Motion Control Application Stories by mikesanye


									                                                                                                                                                                                                                                               Motion Control

                                                                                                                                                        Motion Control Application Stories
                                                                                                                                                                                                                                               Application Stories
                                                                                                                                                                                                                                               Versatile Form Factors to
                                                                                                                                                                                                                                               Meet Diverse Applications

                                                                                                                                                                                                               Flat Panel Display Production
                                                                                                                                                                                                               Semiconductor Production
                                                                                                                                                                                                               SMT/PCB Industrial Assembly
                                                                                                                                                                                                               Electronics Assembly
                                                                                                                                                                                                               Packaging Industry

                                                                                                                                                         Versatile Form Factors to Meet Diverse Applications
Regional Service & Customization Centers
 China                  Taiwan                Netherlands         Poland                 USA
 Kunshan                Taipei                Eindhoven           Warsaw                 Milpitas, CA
 86-512-5777-5666       886-2-2792-7818       31-40-267-7000      48-22-33-23-730        1-877-451-6868

Worldwide Offices
 Great China                              Asia Pacific                       Europe                                Americas
 China                                    Singapore        65-6442-1000      Germany                               U.S.A
   Beijing          86-10-6298-4346                                            Düsseldorf        49-211-97477-0      Cincinnati, OH   1-513-742-8895
   Shanghai         86-21-6282-8959       Malaysia                                                                   Milpitas, CA     1-408-519-3891
   Chengdu          86-28-8545-0198         Penang         60-4-397-3788     France
   Shenzhen         86-755-8212-4222                       60-4-397-4188       Grenoble          33-4-7670-4700    Brazil
   Hong Kong        852-2720-5118         Japan                                                                      São Paulo        55-11-5592-5355
                                            Tokyo          81-3-5212-5789    Italy
 Taiwan                                     Osaka          81-6-6267-1887       Milano           39-02-9544-961
   Taipei           886-2-2218-4567
   Taichung         886-4-2378-6250       Korea                              Netherlands
   Kaohsiung        886-7-229-3600          Seoul          82-2-3663-0405      Roosendaal        31-165-550-505
   Hsinchu          886-3-516-9320
                                          Thailand                           UK
                                            Bangkok        66-2-248-3140       Berkshire         44-1344-989-500

                                            Chennai        91-44-4230-3878

                                            Sydney         61-2-9482-2999
                                            Melbourne      61-3-9797-0100


                                                    2007                                                                               2000002862                                                                                                                
                                                                                                                                                                  Table of Contents
The market for electronics manufacturing is among the biggest
in the world, and more and more of the production is now being                                                                                                    Flat Panel Display Production
outsourced to facilities in the fast-growing economies of Asia.
At the same time, new technologies are being implemented                                                                                                            1   LCD Panel Loader/Unloader             Korea
to minimize inventory, improve quality, and cut design time to
launch products faster than ever before.                                                                                                                            2   TFT Defect Inspection in LCD
                                                                                                                                                                        Panel Assembly
                                                                                                                               Packaging Industry
The outsourcing model of manufacturing has often improved
economies of scale, but has also highlighted the importance
                                                                                                                                                                    3   TFT Defect Repair in LCD
                                                                                                                                                                        Panel Assembly

of a wholistic approach to making products. Manufacturing
needs to be seamlessly integrated with areas that earlier
                                                                                                                                                                    4   TFT Light Testing in LCD
                                                                                                                                                                        Panel Assembly
                                                                                                                                                                                                               P 11

were considered to be different from manufacturing.                                                                                                               Semiconductor Production
• To reduce inventory, the manufacturing of parts needs to
  be linked to the demand for these parts in the factories
                                                                                                                                                                    5   Automated Programmer for
                                                                                                                                                                                                            P 13

  that need them for assembly of systems.
                                                                                                                                                                    6   RAM Module Compatibility
                                                                                                                                                                                                               P 15
• Integration of processes related to design, manufacturing,
  and quality control engineers helps improve quality
  control.                                                                   Flat Panel Display Production
                                                                                                                                                                    7   Laser Marking for Microchips         Taiwan
                                                                                                                                                                                                               P 17

• Design cycle times are being reduced so that                                                                                                                      8   Solder Placement System for
                                                                                                                                                                        BGA/CSP Chipsets
                                                                                                                                                                                                               P 19
  manufacturing teams can achieve volume production                                                                                                               SMT/PCB Industrial Assembly
  as soon as possible, and make their products reach the
  market before anyone else.
                                                                                                                                                                    9   Semi-Automatic PCB
                                                                                                                                                                                                               P 21
Today, hundreds of factories all over the world are seeing
their inventories shrink, and their product development cycle                                                                                                      10   SMT/PCB Line Mounter                 Taiwan
                                                                                                                                                                                                               P 23
                                                                                                                                           Electronics Assembly
being shortened; thanks to equipment based on Advantech                                                                                                                 Auto-Optical Solder                  Taiwan
technologies and system integrator expertise.                                                                                                                           Inspection                              .
                                                                                                                                                                                                               P 25

                                                                                                                                                                   12   Automatic Solder Dispenser       Malaysia
                                                                                                                                                                                                            P 27

                                                                                                                                                                  Electronics Assembly

                                                                                                                                                                   13   Quality Control of Frequencies
                                                                                                                                                                        for Mobile Phones
                                                                                                                                                                                                               P 29

                                                                                                                                                                   14   Keypad Quality Control for
                                                                                                                                                                        Mobile Phones
                                                                                                                                                                                                               P 31

                                                                                                                                                                   15   High-Precision Motion Control
                                                                                                                                                                        for 3D Laser Engraving
                                                                                                                                                                                                               P 33

                                                                                                                                                                   16   Tube Bending Machine                 Taiwan
                                                                                                                                                                                                               P 35

                                                                                                                                                                  Packaging and Others
                                                                  SMT/PCB Industrial Assembly
                                                                                                                                                                   17   Food & Beverage Machine
                                                                                                                                                                                                              P 37

                                                                                                             Semiconductor Production                              18   Metal Injection Molding               USA
                                                                                                                                                                                                              P 39

                                                                                                                                                                   19   Textile Machine Systems               USA
                                                                                                                                                                                                              P 41

                                                                                                                                                                   20   RFID in US Supermarkets               USA
                                                                                                                                                                                                              P 43

 1                                                                                                                                                                                                       2
Complete Application-Ready Platforms for the General                                                                                                                                    Motion Control Market
Advantech offers application-ready platforms that range from industrial workstations and industrial-grade CPUs, to motion control, encoder input and isolated I/O cards for
general motion control (GMC) application such as SMT/PCB, semicondutor and LCD manufacturing machines. As machine automation develops, high speed, effective distance
transmissions, and convenient wiring become increasingly important for system integrators. Advantech Distributed Motion Control (AMONet) is a series of products with innovative
architecture that is designed for versatile industrial automation application, and are especially suitable for distributed motion control requirements.

        Motion Control Configuration

           Distributed Motion Control                                                               Centralized Motion Control                                                                 Embedded Motion Control                                                    Voltage-command Motion Control

                                        AMAX-2212/J2S                                                                                                                                                                                                                                                                     PCI-1241


                                                                                                                                                      PCI-1240U                                                                            UNO-2170
                                                                                                          Mitsubishi                                                                              Mitsubishi                                                                  Mitsubishi

                                        AMAX-2211/PMA                        AMAX-2756

                                                                                                          Panasonic                                                                               Panasonic                                                                   Panasonic
                                                                                                                                        Indicator & Sensor Handwheel & Jog                                               Indicator & Sensor Handwheel & Jog
                                                                                                                                                                                                                                                                                                                           Indicator & Sensor
                                                        Indicator & Sensor

What is the difference between centralized and distributed motion control ?
Machine control system architectures generally fall into two categories - centralized or distributed.                  Centralized Motion Control                                                                                       Distributed Motion Control
In a centralized system, all control loops including logic, trajectory generation, and PID control, are                                                                                                                                                                                                                                                 Master
executed on a single processor on a programmable automation controller (PAC). In a distributed                                                                                                                                                                                        100M
system, the trajectory generation and logic control executes in the central processor, but the
PID control loop is executed in the intelligent slave module. A distributed approach gives more
processing power, while it reduces overall wiring cost and system complexity.
The Distributed Motion Control Products are categorized in two groups - Master Cards and Slave                                                                                                                                                      Slave                        Slave                           Slave                          Slave
Modules. Communication between master and slave is based on a custom-engineered technology
based on RS-485, which saves wires, transmits over long distances at high speeds, and have
time-deterministic features.
The communication interface between master and host PC is based on memory mapping. Various
functions can be chosen on the slave modules, and the industrial DIN-rail mountable design makes                                                                                                               Motion
it easy to distribute them in the field. The master card collects information from slave modules and                                                                                                           Control
publishes the data to its host PC, and vice versa.                                                                                                                                                              Cards
                                                                                                           Sensors and Actuators     Sensors and Actuators     Sensors and Actuators   Sensors and Actuators                     Sensors and Actuators        Sensors and Actuators          Sensors and Actuators       Sensors and Actuators

3                                                                                                                                                                                                                                                                                                                                                                4
1       LCD Panel Loader/Unloader
        Flat Panel Display Production

    Introduction                                                                                    Project Requirements                                  Solution Description                                      Conclusion
LCD screens have replaced CRT’s as the preferable choice for computer monitors, and                 Proprietary control is a very cumbersome              The system has a robotic arm to load or unload the        With the implementation of PC-based AMONet solution, PCI-1202 and ADAM modules, many inefficient
increasingly, TV’s as well. Therefore, LCD production is currently one of the fastest growing       technology. It not only operates under an unpopular   panels from the stack, and conveyers to move panels       areas of the process can be mitigated. The system will have less standby time, higher performance, a
product categories in the consumer electronics market, and rapid growth is expected for             and sophisticated programming language, but it        through the belt. On top of the conveying processes,      lower error rate, and is much more cost-effective. The user can have real-time processing updates and
many years to come. Due to rapid technology development and competitive pressure, an LCD            also consumes a large amount of time for control      there are sensors set up for panel alignment. Finally,    flexibility in modification. Advantech’s AMONet solution also provides the following benefits:
manufacturer in Taiwan switched from a proprietary to a PC-based control system to track            changes. Furthermore, the price of maintaining        the panels are placed to the designated machines
production and utilization information in real-time. This new motion integration control system     proprietary control is quite expensive compared       or into storage with another robotic arm. In the          •Suitable for both standalone and automated systems
not only reduces standby time, but also decreases data acquisition time to improve quality
                                                                                                    to PC-based control. These lead to inefficient and    traditional way, a proprietary system is used to          •SEMI protocol compliant
                                                                                                    expensive manufacturing processes.                    control the robotic arm and a PC-based controller is      The operation information can be integrated into the MES (Manufacturing Execution System) or CIM
                                                                                                                                                          used to integrate the product information with MES        (Computer Integrated Manufacturing) System.
                                                                                                    In order to set up a flexible and PC-based motion     (Manufacturing Execution System). However, this
                                                                                                    control system, the following components are          requires manpower and is very time-consuming.
                                                                                                                                                          The alternate and new solution our customer adopted
                                                                                                    •High-speed motion control card to accurately         is Advantech’s PC-based AMONet module, the PCI-
                                                                                                     control the robotic arm as it moves LCD panels       1202; which provides 20MHz of data transfer speed
                                                                                                     between storage and processing                       (updating 1024 Digital I/O channels within 1.04ms)
                                                                                                    •Slave module with digital inputs to capture          and is capable of fulfilling high-speed control
                                                                                                     information from sensors that detect the             requirements. The PCI-1202 can control and update
                                                                                                     position of the panels on the conveyor belt          both robotic arms and the conveyor through the
                                                                                                                                                          high-speed serial communications. Each robotic and
                                                                                                                                                          sensor station uses Advantech’s ADAM-3752FN/
                                                                                                                                                          3754FN/3756FNN series. Each ADAM acts as a
                                                                                                                                                          medium between mechanical stations and a master
                                                                                                                                                          control, and also provides accurate alignment of the
                                                                                                                                                          glass and error control.

                                                                                                                                                                                                                                                                   Digital Input/Output

                                                                                                                                                                       AMAX-2754                        AMAX-2754                  AMAX-2756                      AMAX-2756               2-port AMONet RS-485
                                                                                                                                                                         32DO                             32DO                     16DI/16DO                      16DI/16DO               Master Card

                                                                                                                                                               Sensor                          Conveyor                   Robot                           Robot

5                                                                                                                                                                                                                                                                                                                       6
2         TFT Defect Inspection in LCD Panel Assembly
          Flat Panel Display Production

    Introduction                                                                                   Project Requirements                                      Solution Description                                  Conclusion
During the LCD manufacturing process, having a zero fault tolerance is almost impossible.          Defect inspection is an extremely important part of       Each camera at the inspection station takes photos    Defect inspection can be a hassle if resources and
Moreover, LCD panels are very delicate products, and can frequently have minor defects.            the production process. It prevents a vicious cycle       of different segments of each LCD panel. The          expansion abilities are limited. With the automated
Therefore, defect inspection is essential at each assembly station. Our customer wanted            by not allowing defects to continue further along the     processed picture will be compared to reference       solution provided by Advantech, more cameras can
to increase the efficiency of their defect inspection stations and speed up their overall LCD      manufacturing process. With the implementation of         pictures for examination. Even though the idea of     be set-up, increasing the defect inspection efficiency,
production. They were using the traditional method of inspection, which consisted of having just   more than one camera, increased processing speed          having more cameras seems obvious, it is limited      and streamlining the entire LCD panel assembly
one camera to complete the process, which is slow and cumbersome. With a new PC-based              and network expansion are necessary. In order to          by the hardware and software capabilities. In         process. Furthermore, it will provide real-time updates
automation solution from Advantech, more cameras can be set up for inspections, allowing a         efficiently inspect each large LCD panel, using a         the old proprietary system, the non user-friendly     and monitoring, effectively upgrading quality control.
smoother and faster production flow.                                                               PC-based operating system is the optimal way.             programming language and poor compatibility
                                                                                                   Furthermore, it allows data communication between         impeded the manufacturing resources.
                                                                                                   the database and each station. To formulate such
                                                                                                   a system, we need the following components to             With Advantech’s automation solution, more cameras
                                                                                                   complete our automated solution:                          can be implemented due to the large expansion
                                                                                                                                                             capabilities, and more motions and commands
                                                                                                   •A master control card for handling all the               can be installed. PCI-1202 is a master control card
                                                                                                     commands and data flow                                  which can be implemented in the PC to process all
                                                                                                   •A motion control card for all the camera                 the motion instructions and data communications.
                                                                                                    orientations                                             As for the inspection station, ADAM-3212/J2S
                                                                                                                                                             can be used for camera or conveyor motions and
                                                                                                   •An isolated Digital I/O card for the command             ADAM-3752/3754 can be used for sensors to
                                                                                                    and handshakes between stations
                                                                                                                                                             ensure the inspection has operated thoroughly.
                                                                                                                                                             Moreover, Advantech’s AMONet has built-in CPU for
                                                                                                                                                             each module and allows Ethernet communication
                                                                                                                                                             between stations. This provides a real-time updates
                                                                                                                                                             and monitoring.

                                                                                                                                                                                                                                                            Digital Input/Output and Motion Control

                                                                                                                                                                                                                                   AMAX-2212/J2S                    AMAX-2212/J2S
                                                                                                                                                                                                                                    1-axis AMONet                    1-axis AMONet
                                                                                                                                                                                                                                     RS-485 Slave                     RS-485 Slave
                                                                                                                                                                       AMAX-2752                     AMAX-2754
                                                                                                                                                                                                                                       Module                           Module             PCI-1202U
                                                                                                                                                                         32DI                          32DO
                                                                                                                                                                                                                                                                                           2-port AMONet RS-485
                                                                                                                                                                                                                                                                                           Master Card

                                                                                                                                                                                                                                            Robot                            Robot
                                                                                                                                                           Conveyor                      Conveyor

7                                                                                                                                                                                                                                                                                                                 8
3          TFT Defect Repair in LCD Panel Assembly
           Flat Panel Display Production

    Introduction                                                                                   Project Requirements                                 Solution Description                                      Conclusion
LCD Panels can have defects that need to be repaired during the panel assembly process.            To be successful, manufacturers have to balance      The repairing system is designed to identify each of      During the manufacturing process, it is inevitable to
Spending resources to find problems, but not being able to solve them in the most efficient        the need for consumer demand, resources and          the damaged pixels and have the coordinates sent          have defects in the products. Having a flexible and
way degrades the flow of the entire process. LCD panels have infinitesimal arrays and cells        competition. Although balancing these factors can    to the mechanical laser arm. Then, the laser will         efficient repairing system will not only maximize
embedded in the panels, and require a precise laser to fix the minor defects in the pixels.        be difficult, the key is to focus on managing day    burn the right spot for damage control. The whole         the whole production quantity but also enhance
Therefore, it is critical to have a flexible and fast repairing system that will efficiently fix   to day production. The most efficient method to      process may seem very simple; however, the data           the quality standard. With Advantech’s PC-based
problems and at the same time not impede the overall flow.                                         manage production is a PC-based distributed motion   acquisition and information flow are extremely            machine automation solution, all the limitations
                                                                                                   control system. It allows for an open architecture   complex. The coordinates may vary from 2D to 3D,          provided by the old proprietary system should not
                                                                                                   with excellent expansion capabilities and high       and the commands for the mechanical arm have to           be a problem anymore. The new repairing system
                                                                                                   compatibility.                                       be extremely accurate due to the size of each array       can meet up with the production flow and increase
                                                                                                                                                        on the panel. With Advantech’s machine automation         the overall quality control.
                                                                                                   To formulate such a system, we need the following    solution, the master card PCI-1202 can handle
                                                                                                   components:                                          different sets of complicated instructions. The
                                                                                                                                                        motion control module ADAM-3212/J2S is capable
                                                                                                   •A master control card for handling all the          of varieties of motion controls that allow different
                                                                                                    commands and data flow
                                                                                                                                                        laser orientations. For the data flow, the Digital I/O
                                                                                                   •A motion control card for the laser positions       card ADAM-3752/3754 has up to 64 inputs and
                                                                                                    and orientations                                    outputs. More controls and data communication
                                                                                                   •An isolated digital I/O card for the command        are feasible. At last, a PC-based system can provide
                                                                                                    and handshakes between stations                     a real-time manufacturing status and keep in track
                                                                                                                                                        of the utilization rate at each station. Therefore, the
                                                                                                                                                        maintenance allows operations at the maximum
                                                                                                                                                        efficient level, and the system can stay in the best

                                                                                                                                                                                                                                                    Digital Input/Output and Motion Control

                                                                                                                                                                                                                                 AMAX-2212/J2S                    AMAX-2212/J2S
                                                                                                                                                                                                                                  1-axis AMONet                    1-axis AMONet
                                                                                                                                                                   AMAX-2752                                                       RS-485 Slave                     RS-485 Slave
                                                                                                                                                                     32DI                                                            Module                           Module            PCI-1202U
                                                                                                                                                                                                                                                                                        2-port AMONet RS-485
                                                                                                                                                                                                                                                                                        Master Card

                                                                                                                                                                                                                                    Robot                          Robot
                                                                                                                                                          Conveyor                          Conveyor

9                                                                                                                                                                                                                                                                                                              10
4         TFT Light Testing in LCD Panel Assembly
         Flat Panel Display Production

 Introduction                                                                                     Project Requirements                                    Solution Description                                     Conclusion
Some manufacturing industries focus on mass production, while others focus on the quality         LCD panels are very delicate products; during the       Due to the complexity of the LCD manufacturing           LCD production is a very time-consuming and
of the product being created. In the growing LCD market, both quality and quantity are in high    assembly process the panels have to be treated          process, orientation and spacing are extremely           precise process. The traditional way of using
demand. An Advantech customer in the LCD market wanted to increase the quality control of         with great care. An efficient light tester is used to   critical. With Advantech’s PCI-1202 and ADAM-            proprietary systems lowers efficiency, is inflexible,
their LCD inspection process, and decided to focus on the lighting inspections for their TFT      confirm correct assembly of the panel, including        3752FN/3754FN modules, sensors make sure                 increases costs and is difficult to maintain. Also it
panels. In such a demanding manufacturing environment, upgrading to a flexible PC-based           the raw panel with driver ICs and the backlight unit.   all the panels are in the right order and correct        is not easy to integrate the production and utilization
machine was the only option.                                                                      Furthermore, position adjustments and function          position on the conveyor. All the push buttons are       information of this station into a CIM/MES system.
                                                                                                  tests require great accuracy and speed. In order to     also integrated within this system. Furthermore, the     With a PC-based testing machine, the process is
                                                                                                  achieve these goals, the following components were      handshake signal between this station and other          now much more cost-effective, and defect rates have
                                                                                                  required:                                               stations (such as in-between material handling and       been decreased. Moreover, the overall efficiency of
                                                                                                                                                          unloading) ensures good traffic control. For the         the entire process has been increased.
                                                                                                  •A motion control card responsible for moving           panels to be accurately mounted into the inverter
                                                                                                   the panels along a conveyor                            for software testing, Advantech’s ADAM-3212/J2S
                                                                                                  •An isolated digital I/O card responsible for           motion control card will control the mechanical
                                                                                                   sensors, push buttons, and the handshake               tilting device and ensure the connectors are fastened
                                                                                                   signals between stations                               to the inverter for the benchmark lighting test. The
                                                                                                  •Master control card for handling all the               panels will then be tilted for engineers due to the
                                                                                                                                                          limitations on the viewing angles for lighting quality
                                                                                                                                                          examination. Once the panel has passed the test, it
                                                                                                                                                          will travel to the next station.

                                                                                                                                                                                                                                                                       Digital Input/Output

                                                                                                                                                                                                                                   AMAX-2212/J2S                    AMAX-2212/J2S
                                                                                                                                                                                                                                    1-axis AMONet                    1-axis AMONet
                                                                                                                                                                                                                                     RS-485 Slave                     RS-485 Slave
                                                                                                                                                                    AMAX-2752                       AMAX-2754
                                                                                                                                                                                                                                       Module                           Module                PCI-1202U
                                                                                                                                                                      32DI                            32DO
                                                                                                                                                                                                                                                                                              2-port AMONet RS-485
                                                                                                                                                                                                                                                                                              Master Card

                                                                                                                                                                                                                                        Robot                            Robot

                                                                                                                                                               Sensor                        Sensor

11                                                                                                                                                                                                                                                                                                                   12
5       Automated Programmer for ICs
        Semiconductor Production

 Introduction                                                                                   Project Requirements                                   Solution Description                                          Conclusion
A handheld electronics manufacturer faced the risk of not meeting customer demands when their   Our customer wanted the system to operate a variety    The automatic pick and place operation runs in the            Accuracy and speed are key elements for pick &
assembly process slowed to a crawl. They wanted to run their machine vision simultaneously      of input and output options with tray, tube and tape   sequence of loading, position, marking, targeting             place programming tools. The variety of motion
with motion control to save time, but the performance of their system became sluggish due to    thus providing programming, marking and packing        programming, sorting and unloading. These steps               control and the large data flow can cause huge
the large memory requirements of the vision software. Our customer needed a major upgrade       conversions for most IC products on/in tray, tube      can be time consuming, and a heavy duty motion                traffic in the assembly process. With Advantech’s
to their assembly system, and wanted an automated system with real-time monitoring.             and tape.                                              control card is required to accomplish such tasks.            motion control PCI-1240U cards, intelligent,
                                                                                                                                                                                                                     accurate operation and high throughput can easily
                                                                                                In order to fully maximize the speed and accuracy,     Advantech’s PCI-1240U, the master control card,               be achieved. Moreover, by implementing Advantech
                                                                                                machine vision is required to perform tasks with       supports these accurate and fast motion controls.             solutions, the pick and place tools are now much
                                                                                                the robotic arm simultaneously, which requires a       Its onboard ASIC incorporates a variety of motion             more accurate and efficient, and the entire process
                                                                                                huge CPU memory cache. It became evident that an       control functions which can be performed without              is now automated with real-time motion control.
                                                                                                integrated PC-based system was required to allow       any processing jams. Moreover, it allows a major
                                                                                                high-performance automated control running in the      upgrade from single manual to dual auto/semi-
                                                                                                conjunction with the machine vision software.          auto. Additionally, large data flow and programming
                                                                                                                                                       control will not be issues anymore. Moreover, the
                                                                                                To achieve such a system, the following components     two precise CCD cameras equipped within the
                                                                                                were required:                                         robotics arms for IC targeting and socket or pick &
                                                                                                                                                       place spot positioning can both be operated under
                                                                                                •A master card controlling all the motions and         the command efficiently and swiftly. Even though the
                                                                                                 data processing
                                                                                                                                                       mechanical and optical operations can be extremely
                                                                                                •A control card commanding actions of each             complex, PCI-1240U can allow both operations to
                                                                                                 station                                               work simultaneously. With Advantech’s PCI-1756,
                                                                                                                                                       all the push buttons, indicator bulbs and the light
                                                                                                                                                       tower are well integrated. Moreover, the PCI-1756
                                                                                                                                                       provides the handshake signals with the tray and
                                                                                                                                                       tube devices.

                                                                                                                                                                                                   Digital Input/Output                                                    64-ch Isolated Digital Output Card

                                                                                                                                                                                                                                        Motion Control                     PCI-1240U
                                                                                                                                                                                                                                                                           4-axis Universal PCI Stepping/
                                                                                                                                                                                                                                                                           Pulse-type Servo Motor Control
                                                                                                                                                                                                                                    Nozzle Mechanism
                                                                                                                                                                      Switch, Button and

13                                                                                                                                                                                                                                                                                                      14
6        RAM Module Compatibility Test
         Semiconductor Production

 Introduction                                                                                  Project Requirements                                      The process starts with loading the dimensions,
                                                                                                                                                         pin assignments, profile, and batch number into the
To improve test speed and accelerate changes in their production line, a large RAM module      The customer’s system used proprietary system for         system computer. A tray of RAM modules is then                 •The new system is entirely based on industrial PCs, meaning maintenance and operation has
manufacturer chose to switch from PLC to PC-based machinery for compatibility testing. The     motion control, which were difficult to operate with      placed in the machine, and the operator presses a                  been considerably simplified
new system, designed with Advantech’s PCI-1240U, and PCI-1750, completely integrates
motion control and data acquisition, dramatically reducing standby time and increasing
                                                                                               the PC-based RAM modules and motherboards used            button to start the test.                                      •The PC-based system provides a larger memory and an open architecture that is easier for
                                                                                               for testing. The basic requirement therefore, was to                                                                         programming and expansion
output.                                                                                        simply implement a PC-based system. Additionally,         PCI-1750 starts by using a digital input for a sensor
                                                                                               the system should have the ability to allow one tray      that detects the presence of the RAM module tray.
                                                                                               of RAM modules to be tested while the second tray         If present, digital output channels are used to turn
                                                                                               is being loaded. Not only would this allow for more       on the activation light and inform PCI-1240U that
                                                                                               efficient operation, but also double the testing speed    it is time to start moving the modules. PCI-1240U
                                                                                               while only requiring one operator.                        responds by using three of its axes to pick the first
                                                                                                                                                         module from the tray and place it into the fixed
                                                                                                                                                         motherboard. When placed, PCI-1750 uses a digital
                                                                                               Solution Description                                      output to turn on the power of the motherboard.

                                                                                                                                                         Software running on the machine’s computer fills the
                                                                                               The system is designed to test compatibility with
                                                                                                                                                         memory of the RAM module with a pattern, which is
                                                                                               RAM modules in common motherboards. For this
                                                                                                                                                         then read back and checked to see if anything had
                                                                                               application, two trays of RAM modules are prepared
                                                                                                                                                         changed. If not, the module has passed the test and
                                                                                               and a pick-and-place tool moves the modules into a
                                                                                                                                                         is placed in an output tray leading to the packaging
                                                                                               motherboard for the compatibility test. After the test,
                                                                                                                                                         machine. If there is an error, the module is moved to
                                                                                               the modules are placed on an output tray.
                                                                                                                                                         a tray for defect modules. No matter what the result
                                                                                                                                                         is, the system records the test result in a database
                                                                                                                                                         over an Ethernet connection, together with the serial
                                                                                                                                                         number of the RAM module.

                                                                                                                                                         The test continues with the pick-and-place tool
                                                                                                                                                         moving to the next RAM module on the tray until
                                                                                                                                                         all are tested. While one tray is being tested, the
                                                                                                                                                         operator prepares the second tray.

                                                                                                                                                                                                     Digital Input/Output                                                   32-ch Isolated Digital I/O and Counter Card

                                                                                                                                                                                                                                      Motion Control
                                                                                                                                                                                                                                                                            4-axis Universal PCI Stepping/Pulse-type
                                                                                                                                                                                                                                                                            Servo Motor Control Card

                                                                                                                                                                     Switch, Button and                                                 Pick & Place Mechanism

15                                                                                                                                                                                                                                                                                                                        16
7       Laser Marking for Microchips
        Semiconductor Production

 Introduction                                                                                       Project Requirements                                   Solution Description                                        Another image is captured of the microchip, this time
                                                                                                                                                                                                                       to verify that the marking has been successful. If not,
One of the final steps in the production of microchips is the printing of the information on the    When the pattern to print on a microchip becomes       The machine loads a pattern file into its memory            this will set off an alarm, and a copy of the image
chip itself. Most chips just have a batch number and logo, but there is a new trend to include      more than just a few dots, transferring it to a        and calibrates the machine vision software so that          will be stored on the system for troubleshooting.
more information and have more complex patterns printed on the chips as well.                       PLC through a decoding program can become              it knows where to print on the microchip, and where         If successful, PCI-1240U turns off the warning
                                                                                                    troublesome. Logos and patterns are often created      to check the finished markings. Microchips are              indicator, and activates the 4th axis to start the
A customer used Advantech’s PCI-1761, PCI-1240U, FPM-3120 and ACP-4001 with a machine                                                                                                                                  conveyor belt that brings the microchip out of the
                                                                                                    in AutoCAD, Pro/E and other PC-based applications.     brought to the machine in a continuous stream on
vision system to create a fully automatic laser marker for microchips. By using PC-based                                                                                                                               machine.
                                                                                                    Using a PC over a PLC allows operators to load these   a conveyor belt.
products, their new system is more powerful, more versatile, and can easily adapt to changes
                                                                                                    patterns directly into the machine instead of having
in the market.
                                                                                                    to go through an additional decoding process. This     One axis of the PCI-1240U is used to control the            Conclusion
                                                                                                                                                           speed of the conveyor belt, which can help ensure
                                                                                                    results in a faster turnaround and the capability to
                                                                                                    have more complex designs.                             there is coordination with other machines in the            •Fully automatic system removes the need for operators
                                                                                                                                                           production line. When a microchip has entered the           •Faster processing for intricate or large patterns compared to proprietary systems
                                                                                                    To fully automate this system, machine vision is       machine, a door closes, and the digital output of           •No need to decode programs between the computer and proprietary systems
                                                                                                    necessary. And for high quality machine vision, the
                                                                                                    captured images are so large that only a computer
                                                                                                                                                           PCI-1240U turns on a warning indicator. A sensor
                                                                                                                                                           detects if the door is closed properly and sends a
                                                                                                                                                                                                                       •Reduced support costs as system can be remotely diagnosed. By using software like PC-
                                                                                                                                                                                                                          Anywhere or NetMeeting to check the machine over the Internet, the need to visit field sites can
                                                                                                    can process them. It was fairly obvious that if the    signal to the PCI-1761.                                        often be eliminated. For this customer, it meant saving several international trips every year
                                                                                                    whole system was PC-based, system integration
                                                                                                    would become easier. The requirement was therefore     When the PCI-1761 receives the signal that the door
                                                                                                    to get a PC-based system to replace the customer’s     is closed, it will initialize the frame grabber card.
                                                                                                    low-performance PLC-based system.                      The frame grabber card captures an image of the
                                                                                                                                                           microchip, and the machine vision software analyzes
                                                                                                                                                           the image and determines the orientation and exact
                                                                                                                                                           position of the microchip. It also sets the reference
                                                                                                                                                           point for the X and Y axes. With the reference point
                                                                                                                                                           now set, the two axes of the PCI-1240U can be used
                                                                                                                                                           to direct the laser beam over the surface.

                                                                                                                                                           Digital output signals from PCI-1240U are used
                                                                                                                                                           to switch the laser on and off during the marking.
                                                                                                                                                           Circular and linear interpolation enables intricate
                                                                                                                                                           patterns. On completion, the laser is moved back to
                                                                                                                                                           its secure position.

                                                                                                                                                                                                                   Digital Input/Output                                                      8-ch Relay Actuator and 8-ch
                                                                                                                                                                                                                                                                                             Isolated Digital Input PCI Card

                                                                                                                                                                                                                                                Motion Control                               4-axis Universal PCI Stepping/
                                                                                                                                                                                                                                                                                             Pulse-type Servo Motor Control

                                                                                                                                                                                 Switch, Button and
                                                                                                                                                                                      Indicator                                                Laser Marking for

17                                                                                                                                                                                                                                                                                                                             18
8        Solder Placement System for BGA/CSP Chipsets
         Semiconductor Production

 Introduction                                                                                        Project Requirements                                       Solution Description                                      Conclusion
The soldering process is a critical stage in the circuit assembly process, as any faults can cause   In a traditional PLC-based system, programming             The concept of a proprietary solder placement             With the combination of Advantech’s UNO-2160 and PCM-3240, having a highly precise and reliable
severe damage to the device. Furthermore, technology improvements and higher consumer                sophistication and poor data acquisition have limited      system is to have a central computer compiling all        solder ball placement system is made possible. In terms of users’ point of views, real-time monitoring
demand for electronic products have forced circuits to evolve smaller and smaller. At the same       efficiency and quality control. Especially for soldering   the data and to provide real time monitoring for the      and data storage allow higher quality control. On the other hand, anti-vibration and a large number of I/O
time, the need for mass production is inevitable; therefore, having a fast and highly precise        BGA or CSP chipsets, the solder placement system           users. Advantech’s UNO-2160 is a compact and              channels decrease the errors and increase the expansion capabilities for the future. There are also few
soldering machine is extremely important. With a PC-based solution, both the demand for mass         requires high quality control and low tolerance for        fanless computing platform with two PC/104 slots          more benefits using these two Advantech products.
production and need to keep pace with technology trends can be met.                                  errors. The newly introduced PC-based solution             allowing high expansion abilities. It has no moving
                                                                                                     has flexible control and real-time monitoring,             parts and excellent vibration resistance. Usually         •SEMI protocol compliant
                                                                                                     and also allows a fully automated operation. In            older compact computing platforms are designed            •Data could be integrated into the MES (Manufacture Execution System) or CIM (Computer
                                                                                                     order to achieve such performance, the following           as proprietary systems, which create bottlenecks            Integrated Manufacturing) system, with a Windows-like GUI for easy operation
                                                                                                     components are required:                                   when connecting to MES system from isolated to
                                                                                                                                                                integrated automations. Therefore, UNO-2160 will
                                                                                                     •A PC-based industrial computer for central                not only allow higher flexibilities, but also generate
                                                                                                       processing with high-speed performance                   larger data processing abilities.
                                                                                                     •Highly precise soldering process for small
                                                                                                       components                                               The role of an embedded motion control card is to
                                                                                                                                                                accurately control the solder printer. The printing
                                                                                                                                                                precision and motion are very critical in the soldering
                                                                                                                                                                process. They do not allow any movements that will
                                                                                                                                                                cause inaccuracies. Therefore, we recommended
                                                                                                                                                                Advantech’s PCM-3240 for this solution. It can
                                                                                                                                                                provide 4-axis pulse-type servo or stepping motor
                                                                                                                                                                control, and moreover, its compact size can be fitted
                                                                                                                                                                inside the chassis of an UNO-2160, yet provide the
                                                                                                                                                                same functions as a standard industrial computer
                                                                                                                                                                and plug-in motion control card.

                                                                                                                                                                PCM-3240 has 12 channels of digital input and 16
                                                                                                                                                                channels of digital output which allow high bits for
                                                                                                                                                                highly precise motor and sensor controls.

                                                                                                                                                                                                   Digital Input/Output

                                                                                                                                                                                                                                                                                       4-axis Stepping/Pulse Servo
                                                                                                                                                                                                                                                                                       Motor Control Card


                                                                                                                                                                                                                                                          Solder Paste Printer
                                                                                                                                                                      Switch and Button                                                                       Mechanism

19                                                                                                                                                                                                                                                                                                                              20
9        Semi-Automatic PCB Separator
         SMT/PCB Industrial Assembly

 Introduction                                                                                   Project Requirements                                       For more precise separation, machine vision
                                                                                                                                                           software is used to set the cutting coordinates. A
After many tough years, the PCB industry has learned that survival relies on investing in new   •To deal with the demand for smaller PCBs, the             picture is taken of the PCB and cutting coordinates       •The use of PCI-1240U together with machine vision software has resulted in a PCB separator
equipment and technology. Chief among the new PCB markets is mobile communications, where         system had to be very precise                            are calculated and sent by the machine vision               with cutting precision of ±0.01 mm
handsets need highly compact and flexibly shaped PCBs. To meet this demand, a machine
builder in China used Advantech chassis, I/O and motion control products to create a new
                                                                                                •PCBs for handsets required rounded and                    software to the PCI-1240U motion control card.
                                                                                                                                                           The laser starts cutting the PCB, using PCI-1240U’s
                                                                                                                                                                                                                     •The interpolation features of PCI-1240U made it unproblematic to perform cutting of rounded and
                                                                                                 irregular edges                                                                                                      irregular PCB shapes
general-purpose PCB separator. The new machine offers high precision, and allowed separation                                                               interpolation features for the rounded and irregular
of complex PCB shapes.                                                                          •Integration with machine vision software                  shapes. PCI-1750 is used for on/off control of the        •With a PC-based system, integration with machine vision software was quick and easy
                                                                                                 needed to be easy and simple
                                                                                                                                                           laser beam.                                               •The customer was so pleased with the semi-automatic PCB separator that another fully-
                                                                                                                                                                                                                      automatic model has since been designed with Advantech products
                                                                                                Solution Description                                       At completion, the laser is secured, the warning
                                                                                                                                                           light is switched off, and the fixture moves out
                                                                                                A PCB separator is used to cut PCB boards into             from the separation area while a second fixture
                                                                                                separate circuits. By keeping several identical circuits   moves simultaneously into the separation area. The
                                                                                                on the same physical board during component                operator picks up the fixture with complete PCBs
                                                                                                placement, the pick-and-place tools do not have to         and replaces it with a new one.
                                                                                                be changed out so often. This speeds up component
                                                                                                placement, which usually is the bottleneck of a PCB
                                                                                                production line.                                           Product Implementation
                                                                                                The system starts with the operator placing a fixture      •PCI-1240U is a 4-axis universal PCI stepping/
                                                                                                                                                            pulse-type servo motor control card, and was
                                                                                                filled with PCB boards into the machine. When the
                                                                                                                                                            used to control the laser movement in this
                                                                                                fixture is in place, the operator presses a button to
                                                                                                activate the PCB separator. PCI-1750 captures the
                                                                                                button signal with an input channel and uses an            •PCI-1750 is a 32-ch isolated digital I/O
                                                                                                output channel to move the fixture to the separation        and counter card, used for simple fixture
                                                                                                area. A sensor confirms that the fixture is in place        movement, sensor input signals, operator
                                                                                                by sending a signal to an input channel on PCI-             interface communications, and on/off control
                                                                                                1750. This unlocks the secured laser cutter, turns          for the laser
                                                                                                on the warning light, and initiates the machine vision     •Both cards are placed in an IPC-644 4-slot
                                                                                                software.                                                   MicroBox Desktop/Wallmount Chassis for
                                                                                                                                                            compact and protected storage

                                                                                                                                                                                                                                                                            32-ch Isolated Digital I/O and
                                                                                                                                                                                              Digital Input/Output                                                          Counter Card

                                                                                                                                                                                                                                   Motion Control
                                                                                                                                                                                                                                                                            4-axis Universal PCI Stepping/
                                                                                                                                                                                                                                                                            Pulse-type Servo Motor Control
                                                                                                                                                                       Switch, Button and                                        Miller Mechanism                           Card

21                                                                                                                                                                                                                                                                                                                 22
10           SMT/PCB Line Mounter
             SMT/PCB Industrial Assembly

 Introduction                                                                                   Project Requirements                                 Solution Description                                        Conclusion
In the electronics industry, mass production has become a necessity for any manufacturer who    In the manufacturing process for PCB boards,         One of the current implementations uses a PLC to            Keeping pace with new technology trends is always difficult. With a PC-based pick-and-place machine,
hopes to succeed. To keep pace with market demands, the traditional methods of manual labor     complexity and preciseness are extremely critical.   control the nozzle, and a PC-based controller to            however, our customer will have luxury of expansion capabilities, and increase their overall efficiency. The
have become obsolete; so much so that no company can survive without the help of an automated   With a PC-based automated pick & place machine,      integrate product information to MES. However,              goal of staying on top of the high manufacturing status can be fulfilled.
solution. PC-based pick & place machines can quickly and accurately place the right component   the entire manufacturing process is much more cost   this is not very efficient; the need to maintain two
to the right place, with live updates. Our customer wished to upgrade to an automated pick &    effective. Furthermore, it increases high-density    different technologies is cumbersome and time               •High speed placement of smaller SMT components
place machine to increase their production and streamline their manufacturing process.          interconnect (HDI) and high layer count (HLC). In    consuming. The newly proposed solution with a               •Low loss ratio improving placement reliability
                                                                                                order to formulate such a machine, the following
                                                                                                control components are required:
                                                                                                                                                     plug-in motion control card integrates nozzle control
                                                                                                                                                     and production information to MES in one system,
                                                                                                                                                                                                                 •Using a PC-based system to reduce the system cost and easy to expand
                                                                                                                                                     and can be made possible with Advantech’s PCI-              •PC-based architecture can be integrated with MES to achieve low loss ratio, improving placement
                                                                                                •A central control card to manage motion and         1240U. PCI-1240U provides 4-axis stepping and
                                                                                                 data processing                                     pulse-type motion control. Moreover, the onboard
                                                                                                •A motion control card to command the                intelligent motion ASIC builds in a variety of motion
                                                                                                 movements of the mechanical station                 control functions such as 2/3-axis linear interpolation,
                                                                                                                                                     circuit interpolation, T/S-curve acceleration and
                                                                                                                                                     deceleration. These functions can be performed
                                                                                                                                                     without processor loading during operation.

                                                                                                                                                     Another important process in the automation solution
                                                                                                                                                     is quality control. There should be sensors checking
                                                                                                                                                     the quality and accuracy of each PCB board.
                                                                                                                                                     Advantech’s PCI-1756 provides 32 isolated digital
                                                                                                                                                     inputs and 32 isolated digital outputs with channel-
                                                                                                                                                     freeze functionality. It allows reset protection function
                                                                                                                                                     which enables the default configuration in the event
                                                                                                                                                     of an incorrect operation during an unexpected
                                                                                                                                                     system reset. The final product quality can be easily
                                                                                                                                                     ensured, and overall, the performance level can be
                                                                                                                                                     raised significantly.

                                                                                                                                                                                       Digital Input/Output

                                                                                                                                                                                                                                                                                       64-ch Isolated Digital I/O Card

                                                                                                                                                                                                                                    Motion Control

                                                                                                                                                                                                                                                                                       4-axis Universal PCI Stepping/
                                                                                                                                                                                                                                                                                       Pulse-type Servo Motor Control
                                                                                                                                                                                                                                          Nozzle Mechanism
                                                                                                                                                          Switch and Button                  Sensor

23                                                                                                                                                                                                                                                                                                                       24
11         Auto-Optical Solder Inspection
           SMT/PCB Industrial Assembly

 Introduction                                                                                       Project Requirements                                     inspection. These systems work independently
                                                                                                                                                             within the machine providing a combined solution.
Printed Circuit Boards are used in virtually every electronic device today, from cellular phones    Our customer was using an outdated system that                                                                             By combining Advantech’s PCI-1240U and PCI-1751U cards, a high-performance, highly reliable, and
and personal computers to industrial and medical machinery. One of the most integral steps in       required 2 expensive machines, one for machine           In this application, the motion “trajectories” are sent           cost-effective solution was found. The customer now had 1 machine that controlled machine vision and
assembling Circuit Boards is the solder placement.                                                  vision and one for machine control. Furthermore, this    from the host to the drives. The drives interpret the             motion control, with 3D solder inspection capabilities. Furthermore, the system provided the following
                                                                                                    system was only capable of 2D solder inspection,         trajectories and drive the servo motors accordingly.              benefits:
Our customer was having issues in the creation of their Circuit Boards with misplaced and weak                                                               The drives also run supervisory monitoring programs
                                                                                                    which is not good at judging the corners/angles of
solder joints. Furthermore, they were using 2 separate machines for 2D solder inspection. To
                                                                                                    the placement and can cause weak connections,            and can execute a programmed script that is stored                •3D solder paste printing inspection machine
save costs, increase reliability, and speed up the inspection process, the customer wanted
only 1 machine that could handle machine vision and control with 3D solder inspection
                                                                                                    leading to faulty boards and potential short-circuits.   in flash memory.                                                  •Ultra simple and highly precise in-line PCB inspection system
                                                                                                    They desired to have an entirely new system, with
                                                                                                    the following requirements:
                                                                                                                                                             Previously, a centralized controller with a PC front-             •Ultra high-speed inspection
                                                                                                                                                             end was used to interface with I/O pneumatics                     •Real-time judgments of failed patterns
                                                                                                    •They wanted 1 machine that could handle                 and the motion system. This put the burden of the                 •High-speed and easy Human Machine Interface
                                                                                                     both machine vision and control                         machine control on a single processing system in
                                                                                                                                                             which all devices received commands and reported                  •SPC (Statistical Process Control) System providing Online fault Pareto listing
                                                                                                    •The system needed to have 3D solder                     back data (feedback position, sensor state, etc.).                The main purpose of an SPC (Statistical Process Control) System is to collect quality-related data during
                                                                                                     inspection capabilities
                                                                                                                                                                                                                               production process for further statistical analysis, and to discover any abnormality in the production
                                                                                                    •They wanted a higher-performance PC-based               Advantech’s PCI-1240U was applied for the high-                   process.
                                                                                                     system                                                  speed motion control, giving the added performance
                                                                                                    •The system needed to have high inspection               from motors. For the I/O card architecture,
                                                                                                     accuracy with high-speed motion control                 Advantech’s PCI-1751U DI/O card is applied, helping
                                                                                                                                                             the moving motor control different lighting for visual
                                                                                                    •They wanted a system that required less                 judgment, which helps make the inspection clear
                                                                                                                                                             and reliable.

                                                                                                    Solution Description                                     Having two subsystems running independently
                                                                                                                                                             (automatic soldering application and automatic
                                                                                                                 The system is comprised of an Optical       visual inspection) with the ability to interact with
                                                                                                                 Inspection machine which examines           each other for coordinated motion, allowed the
                                                                                                                 the surface of the PCB board. In the        overall machine to provide 20% more throughput.
                                                                                                                 machine architecture, there are 2           This, coupled with a quicker changeover process,
                                                                                                                 subsystems, one for moving the PCB          provided greater machine utilization when smaller
                                                                                                                 board and the other for visual quality      production runs dictated machine usage.

                                                                                                                                                                                                                       Digital Input/Output                                                     48-bit Universal Digital I/O and
                                                                                                                                                                                                                                                                                                Counter Card

                                                                                                                                                                                                                                                Motion Control

                                                                                                                                                                         Switch, Button and                                                                                                     4-axis Universal PCI Stepping/
                                                                                                                                                                              Indicator                                                          Optical Inspection                             Pulse-type Servo Motor Control
                                                                                                                                                                                                                                                     Mechanism                                  Card

25                                                                                                                                                                                                                                                                                                                                  26
12            Automatic Solder Dispenser
              SMT/PCB Industrial Assembly

 Introduction                                                                                    Project Requirements                                      Solution Description                                          Conclusion
According to Moore’s Law, the number of transistors doubles on integrated circuits every 18      Soldering components on each SMT/PCB board is             The purpose of a dispenser is to enhance mounting             As technology thrives, the role of the dispenser is
months. This shows that the electronic components become smaller and more complex as             not a simple task. It not only requires identifying the   large-sized components on SMT/PCB boards.                     necessary in the process of manufacturing SMT/PCB
technology improves. For SMT/PCB board, same story applies. More components are needed           orientation of the board, but also adjusts the quantity   When a SMT/PCB board is on a move through the                 boards. With the help of Advantech’s automation
to be implemented and the gaps between pins are narrower. Therefore, it is inevitable to have    of the glue for each component on the board. Thus,        assembly line, there is a tendency that the large             solution, the combination of PCI-1756 and PCI-
an accurate and fast dispenser for mass production. With Advantech’s automation solution,        the dispenser needs to have a large data flow and         components may shift out of the position. Therefore,          1240U can support the needs of a dispenser and
the PC-based operating system can cope with the technology growth and future trend.              allows a variety of soldering motions. To formulate       the glue from the dispenser between the board and             fully operate to its maximum efficiency.
                                                                                                 such a system, we need the following components:          components are used to ensure an accurate and
                                                                                                                                                           stable placement.
                                                                                                 •A motion control card commanding all the
                                                                                                  movements                                                Before any glue can be implemented, the sensor
                                                                                                 •An isolated digital I/O card for data                    needs to detect the order of the board for traffic
                                                                                                  communications and handshakes                            control. Furthermore, it ensures the perfect
                                                                                                                                                           orientation for the components on the board
                                                                                                                                                           avoiding the future short or open circuit problems.
                                                                                                                                                           With Advantech’s PCI-1756, a variety of sensors
                                                                                                                                                           can be implemented possible. It allows a large data
                                                                                                                                                           flow between stations, and more external controls
                                                                                                                                                           are enabled.

                                                                                                                                                           For the central control, Advantech’s PCI-1240U is
                                                                                                                                                           the best choice for the job. It not only allows a variety
                                                                                                                                                           of motion movements for gluing, but also keeps
                                                                                                                                                           tracks of traffic control. Large data flow of the I/O
                                                                                                                                                           and the device itself will not be a problem. Moreover,
                                                                                                                                                           the control card is PC compatible which also means
                                                                                                                                                           a large expansion capability.

                                                                                                                                                                                                  Digital Input/Output
                                                                                                                                                                                                                                                                               64-ch Isolated Digital I/O Card

                                                                                                                                                                                                                                                  Motion                       4-axis Universal PCI Stepping/
                                                                                                                                                                                                                                                  Control                      Pulse-type Servo Motor Control

                                                                                                                                                                            Switch, Button and                                                    Dispenser Mechanism

27                                                                                                                                                                                                                                                                                                               28
13           Quality Control of Frequencies for Mobile Phones
             Electronics Assembly

 Introduction                                                                                    Project Requirements                                      The steps are repeated two more times to test 1.8
                                                                                                                                                           GHz GSM and GPRS signals.
                                                                                                                                                                                                                    Project Implementation
The high cost of state-of-the-art quality control systems for mobile phones has created a
demand for more cost-effective alternatives. A leading ODM mobile phone manufacturer in
                                                                                                 Although a fully-automatic system would be ideal,
                                                                                                                                                           Software takes care of switching from one test           •Agilent 8960 Test instrument with 2 frequency input channels
                                                                                                 there are usually many different mobile phone
Taiwan found such an alternative with Advantech. Standard products from Advantech were           models running on a production line. It is therefore      mode to the next, so the operator simply places
used to verify GSM and GPRS signals of mobile phones. The basic quality control procedure
for frequencies used to require the phone to be tested, an operator, a test instrument, and a
                                                                                                 rarely cost-effective to replace an operator with a       mobile phones into the fixture, and listens to audio
                                                                                                                                                           signals to see if the phone passes the test. After the
                                                                                                 robotic arm to move mobile phones in and out of the
test station. This test would take approximately 1 minute per phone.                             test stations. The goal here is therefore to reduce the   three modes have been tested, the test results are       •Increased output of approximately 1,200%
                                                                                                                                                           automatically stored in a database together with the
After implementing the new test equipment, the testing time was reduced to one operator using
                                                                                                 working process of the operator to the simplest tasks
                                                                                                                                                           product’s serial number. The operator removes the
                                                                                                                                                                                                                    •Fewer human errors with automated quality control
4 test stations to simultaneously check 4 phones in 20 seconds; an output improvement of
                                                                                                 possible. In this case, the process was reduced to
                                                                                                 placing and removing mobile phones from a test            phones from the fixtures, and replaces them with         •More efficient usage of equipment with one operator using four test stations and two instruments.
1,200%. Reduced human error was another bonus, and the entire process is now accomplished
                                                                                                 station, discarding any malfunctioning units.             four new phones.                                         •Scalability. The system diagram shows a system where the Agilent instruments are the bottleneck
at the fraction of the cost of a high-end, quality control system.                                                                                                                                                   as they only have two input channels. The cards currently in this system together with eight
                                                                                                                                                           Before this system was implemented, the operator          instruments with two channels each would have a capacity of 16 phones
                                                                                                                                                           would have to manually adjust the instrument to
                                                                                                 Solution Description                                      the wanted frequency range. Then dial out using
                                                                                                                                                                                                                    •Adaptable; minor modifications can make the system capable of running many similar tests
                                                                                                 The new process starts with an operator placing
                                                                                                                                                           the keypad of the mobile phone, and check if the         •Open standard; a variety of suppliers for all components in the solution
                                                                                                                                                           frequency was correct by reading the frequency
                                                                                                 4 mobile phones into the 4 test stations, and then
                                                                                                                                                           displayed on the instrument. The test data was then
                                                                                                 pressing a button to start the test. The PCI-1762
                                                                                                                                                           entered into a database by hand. Obviously, there
                                                                                                 is used as a multiplexer to switch between output
                                                                                                                                                           was room for many human errors as one minute
                                                                                                 channels, creating a connection between the analog
                                                                                                                                                           was not much time to complete all the required
                                                                                                 signals from the PCI-1723 and the mobile phones.
                                                                                                 PCI-1723 sends an analog output signal to each of
                                                                                                                                                           Although this solution is specific for mobile phones,
                                                                                                 the mobile phones. This simulates a dial-out signal,
                                                                                                                                                           similar solutions can be used for testing PDAs,
                                                                                                 and the phone responds by sending out a 900 MHz
                                                                                                                                                           CD-ROMs and other electronics. Together with
                                                                                                 GSM signal. This signal goes to the Agilent 8960
                                                                                                                                                           Advantech engineers, you can develop a customized
                                                                                                 instrument, which measures the frequency and
                                                                                                                                                           solution that removes the bottlenecks in your quality
                                                                                                 passes this information on to IPC-6806 via the
                                                                                                                                                           test system.
                                                                                                 PCI-1670 GPIB card. The measured frequency is
                                                                                                 captured by software and beep codes are output to
                                                                                                 signal to the operator if the frequency is within the
                                                                                                 acceptable range. (Visual signals are also possible
                                                                                                 with VGA output to a screen).

                                                                                                                                                                                                                                                                              Relay Actuator and Isolated D/I Card
                                                                                                                                                                           Agilent 8960
                                                                                                                                                                    Verify GSM, GPRS Signal                                                                                   PCI-1723
                                                                                                                                                                                                                                             Relay                            Non-isolated Analog Output Card

                                                                                                                                                                                                                                                                              GPIB Interface PCI-bus Card
                                                                                                                                                                           Agilent 8960
                                                                                                                                                                    Verify GSM, GPRS Signal

29                                                                                                                                                                                                                                                                                                                   30
14            Keypad Quality Control for Mobile Phones
              Electronics Assembly

 Introduction                                                                                      Project Requirements                                         in voltage levels defines the color. By testing these
                                                                                                                                                                voltage signals with PCI-1711L, correct color
One of the basic tests in the Quality Control of mobile phones is checking the output signals      In mobile phone production lines there are usually           display can also be tested.                               •The new system has led to clear productivity and quality improvements. The keypad functionality
after pressing keys on the keypad. This can be done manually by an operator (pressing the          many different models being quality tested                                                                              test has reduced testing processes from a minute to 5 seconds, and test accuracy has increased
keys one by one and verifying the signal output with a multimeter), but a far more efficient       simultaneously, making it very problematic to depend         After verifying the various functions of the first key,    from 95.7% to 100%
and quality-assuring process can be created with a few Advantech I/O cards and a fixture. A                                                                     a signal goes to PCI-1758UDIO to inform that it can
leading ODM mobile phone manufacturer in China created a solution with the PCI-1758UDIO
                                                                                                   on a fully automated system. Human operators are
                                                                                                                                                                proceed to the next key. The process continues to         •The system is adaptable as minor modifications can make the system capable of running many
                                                                                                   required in order to manually place each phone                                                                          similar tests, and adding identical cards can increase capacity
to drive mechanical silicon fingers, and a PCI-1711L to capture the output signals from the        into a corresponding test station, and make quick            check each key on the keypad. When complete, a
phone. This simplified the operator’s tasks, reduced errors, and increased the overall speed       judgments when discarding malfunctioning units. In           digital output channel is used to alert the operator      •With open standard components, there is a choice of suppliers for the application
and efficiency of the testing process.                                                             this type of production line, it is better to increase       so that the tested phone can be exchanged with a
                                                                                                   the efficiency of human operators rather than work           new one.
                                                                                                   towards creating an automated system.
                                                                                                                                                                If a key press results in an error, it can halt the
                                                                                                                                                                output of signals for the silicon fingers, and wait
                                                                                                                                                                for operator action. The system can also record the
                                                                                                   Solution Description                                         error into the database together with information
                                                                                                                                                                on where in the test procedure the error occurred
                                                                                                   The process starts with the operator placing the
                                                                                                                                                                and the serial number of the product. This makes it
                                                                                                   phone in the test station’s fixture and pressing a
                                                                                                                                                                easier for production engineers to troubleshoot the
                                                                                                   button. This sends a signal to a digital input channel
                                                                                                                                                                production line and do quicker repairs.
                                                                                                   on PCI-1758UDIO, which initiates the test program
                                                                                                   on IPC-6806. The test starts with PCI-1758UDIO               The system diagram shows a well balanced system
                                                                                                   sending a digital output signal to a relay on the fixture,   to test four phones simultaneously, but can easily be
                                                                                                   which starts the mechanical process of pressing a            scaled by adding more cards. PCI-1758UDIO can
                                                                                                   silicon finger towards the first key on the phone’s          activate the 16 numeric keys on four phones with its
                                                                                                   keypad. At touchdown, several functions will activate        64 output channels.
                                                                                                   (depending on phone model).
                                                                                                                                                                The 16 digital inputs of PCI-1711L are used to
                                                                                                   If a numeric key is activated, a digital output code         capture the digital touchtone codes (four channels
                                                                                                   for the Touchtone signal is output to PCI-1711L, and         per phone), while the 16 analog inputs are used for
                                                                                                   compared to the correct codes by software.                   testing the LCD, LEDs and speaker. The 16 digital
                                                                                                                                                                outputs can be used to activate more silicon fingers
                                                                                                   Pressing a numeric key should also make the speaker
                                                                                                                                                                for extra function keys, bringing the maximum
                                                                                                   of the phone output an analog output signal at the
                                                                                                                                                                number of keys on a phone up to 20.
                                                                                                   correct frequency. This is tested by an analog input
                                                                                                   of PCI-1711L. For color LCD displays, the difference

                                                                                                                                                                  Active Silicon
                                                                                                                                                                     Fingers                                                                                                                  PCI-1758UDIO
                                                                                                                                                                                                                                                                                              128-ch Isolated Digital I/O

                                                                                                                                                                                                                                                                                              100 kS/s, 12-bit , 16-ch S.E.
                                                                                                                                                                                                                                                                                              Input Low-cost Multifuction
                                                                                                                                                                                                                                                                                              Card w/o AO Function

                                                                                                                                                                                                                                                      Color LCD Display

31                                                                                                                                                                                                                                                                                                                          32
15           High-Precision Motion Control for 3D Laser Engraving
             Electronics Assembly

 Introduction                                                                                  Project Requirements                                      The 4th axis of the motion control card is used
                                                                                                                                                         to move the laser from its secure position to the
Although lasers have become a widely accepted tool in the industrial market, many 3D laser     A customer needed to engrave 3D patterns with over        engraving position, while a digital output signal is            •The new solution doubled the speed from 500 kbps to 1 Mbps, saving the customer time &
engraving machines are still being driven by proprietary systems. While functional, these      10,000 cuts into tiny plastic cubes. To engrave these     used to light up a warning indicator to show that the              money and effectively doubling their output
systems lack the high-performance and high-accuracy capabilities that many of today’s
demanding optoelectronic applications require.
                                                                                               intricate patterns on such a small scale requires an      laser is active. A digital output of PCI-1240U is used
                                                                                                                                                         to switch on the laser that carves the first point of
                                                                                                                                                                                                                         •By moving from their old proprietary system to a PC-based system, training operators became
                                                                                               extremely accurate laser with precise control of                                                                           easier, and the complexity of patterns could be increased due to the higher memory and storage
                                                                                               timing, energy, and accuracy.                             the first layer.                                                 capacity. Programming the PC was also cheaper than earlier proprietary programming, and with
For a machine producer in China, Advantech products were used for upgrading their laser
                                                                                                                                                                                                                          the high costs of proprietary system, this PC-based solution was clearly a more economical
engraving system to a PC-based system with higher performance, higher accuracy, increased      Additionally, our customer wanted to increase             PCI-1240U switches off the laser after the allocated             solution
speed, and better stability.                                                                   their production runs. This could be accomplished         time, as the size of the cut depends on the time spent
                                                                                               through quicker loading of the pattern files into the     engraving. The table moves to the next point on the             •The new system has more precise position control for the lenses and the moving table.
                                                                                               production line.                                          same layer where PCI-1240U again fires the laser.               •The on/off switching time is shorter
                                                                                                                                                         When all points on the same layer have been carved,
                                                                                                                                                         PCI-1240U moves the table down along the Z-axis
                                                                                                                                                                                                                         •The patterns could be changed much easier, which means that shorter production cycles were
                                                                                               Solution Description                                      to create a higher layer of cuts. On completion, the
                                                                                                                                                         laser is moved back to its secure position and the
                                                                                               The process starts with the operator placing a tray       warning indicator is switched off. The operator takes
                                                                                               of 12 plastic cubes onto the machine’s fixture, and       the tray with crystals and replaces it with another.
                                                                                               then loading the 3D pattern file. A button is pressed
                                                                                               on the fixture to start the laser engraving process.

                                                                                               A signal is sent to a digital input channel on the PCI-
                                                                                               1240U motion control card, the pattern file is read,
                                                                                               and the moving table goes to the highest point of the
                                                                                               vertical Z-axis and the starting point for the X and Y
                                                                                               axes. The twelve mirrors and lenses are moved in
                                                                                               position over the 12 cubes.

                                                                                               By engraving one horizontal layer at a time, a simple
                                                                                               stepping motor can be used for vertical control,
                                                                                               while a more complicated servo motor can be used
                                                                                               for horizontal control to allow greater speed.

                                                                                                                                                                                                                  Motion Control and Digital Input/Output

                                                                                                                                                                                                                                                              4-axis Universal PCI Stepping/Pulse-type Servo
                                                                                                                                                                                                                                                              Motor Control Card

                                                                                                                                                                                                          Laser and 3-axis Robot

33                                                                                                                                                                                                                                                                                                                      34
16            Tube Bending Machine
              Electronics Assembly

 Introduction                                                                                     Project Requirements                                     Solution Description                                     Conclusion
As creative technology improves, new metal alloys have become stronger, lighter, and more         Metal tube bending machines may seem simple,             Bending machines function by taking advantage of         In order to operate such a delicate job, using voltage command motion control cards from Advantech
durable. Many of these new metal products are being used in the airplane and aerospace            but hidden behind the bulky machinery lies complex       separate motors to create differential torque. A tube    is the optimal solution. The high bit control and data acquisition rates ensure quality and preciseness of
industries, which require strong, light metal tubes with complex shapes and curves. Therefore,    software programs that are the result of years of        traveling through the motors will be bent due to this    the tube.
having a quality PC-based bending machine is extremely important to ensure correct bending        research. To ensure that bending does not weaken         opposing force. Sensors will then perform quality
angles, appropriate stress limits, and to provide real-time motion control.                       the tube, the machine has to take some factors           checks on the bent tube to ensure proper shape and       •PC’s are easily selected by touch limiting potential errors
                                                                                                  into consideration, such as the materials’ property,     smoothness. For a voltage type driver controlling        •Computer modem dial up link with factory service center for software upgrades and operational
                                                                                                  density, weight, size, angle, shape, and more.           motor speed and torque, Advantech’s PCI-1241 uses         assistance
                                                                                                  Normally the machine makers utilize PC-based
                                                                                                  software to analyze these parameters, and then
                                                                                                                                                           an ASIC with a DDA (Digital Differential Analyzer) for
                                                                                                                                                           4-axis servo positioning and synchronizing controls
                                                                                                                                                                                                                    •Operators can set up the pop feeding/stop position and protection device for easier control and
                                                                                                  transfer the profile into a specific data format to      in order to evenly move the axis. Furthermore, the
                                                                                                  meet the proprietary machine controller’s language.      closed-loop control is implemented with P control,
                                                                                                  This can be costly, however, as it requires at least     and -10 to +10V signals are used for outputs to the
                                                                                                  two engineers to handle the PC-based software and        servo motor driver. With PCI-1241’s 128 isolated
                                                                                                  machine controller. By adopting a PC-based machine       digital input and outputs, functional expansions are
                                                                                                  controller, material analysis and data transfer can be   made possible.
                                                                                                  achieved while saving time and money. In order to
                                                                                                  formulate such a machine, we need the following          Before any bendling can be implemented, the sensor
                                                                                                  components:                                              needs to detect the metal tube for length control.
                                                                                                                                                           Furthermore, it ensures the perfect shape for the
                                                                                                  •A card to act as the master; to control the data        metal tube avoiding the unexpected operation. With
                                                                                                    and communication between stations                     Advantech’s PCI-1756, a variety of sensors can be
                                                                                                  •A high rate controlling card to manage the              implemented. It allows a large data flow between
                                                                                                    motion of each mechanism                               stations, and more external controls are enabled.

                                                                                                                                                                                      Digital Input/Output
                                                                                                                                                                                                                                                                                 64-ch Isolated Digital I/O Card

                                                                                                                                                                                                                               Motion Control

                                                                                                                                                                                                                                                                                 4-axis Voltage-type Servo Motor
                                                                                                                                                                                                                                                                                 Control Card

                                                                                                                                                               Switch and Button              Sensor
                                                                                                                                                                                                                                         Bending Mechanism

35                                                                                                                                                                                                                                                                                                                        36
17            Food & Beverage Machine System
              Facility Management

 Introduction                                                                                          Project Requirements                                        Solution Description                                          Conclusion
Providing safe and tasty food with an extended shelf life, while meeting growing concerns              Automated Food Machines require detailed process            The food machine system is a dispatch sender for              •Flexibility, Visualization, Expandability
regarding the use of salt, sugar, fats, additives, and preservatives, is an increasingly difficult
challenge for the food industry. Recent developments in equipment and motor control
                                                                                                       control; including highly specific ingredient quantities,   various sauce recipes. The ADAM-5550KW works                  •After working closely with a major food service client, Advantech helped implement a new
                                                                                                       food quality, sanitation, manufactured date,                as main controller with built-in SQL Mobile Server             automated control scheme that provides PC’s computing performance and PLC’s robustness as a
technology have helped the food industry to create a wide range of food making machines                inspection, seal processes, and more. In past years,        for data and recipes exchange.                                 new generation integration of proprietary controls with a convenient user-interface (Human Machine
that have greater accuracy ingredient handling. By improving the accuracy of mechanical                proprietary control was good enough for simple food                                                                        Interface) to create an efficient automatic process. Now the operator can work with or without
recipe proportioning, pre-processed foods are more balanced, taste better, and clearly reflect         processes. In today’s growing health conscious              The HMI function is integrated by directly attaching           display/keyboard/mouse which can meet different requirements of applications
the ingredients listed on the package, so consumers are aware exactly of what they are                 world, however, consumers are demanding foods               an LCD panel to the VGA port running HMI software
getting. Recently, a customer turned to Advantech to improve their automated food packaging            with specific quantities of salt, sugar, fat, etc.          on the ADAM-5550KW through the membrane                       •This new process not only allows operators to easily change production lines by loading new
machines and increase their control and machine efficiency.                                                                                                                                                                       recipes and maintaining a database of common ingredients, but also allows the machines to create
                                                                                                       Furthermore, many popular instant foods rely heavily        keypad.                                                        highly specific recipes which reflect in the final product being healthier, and tasting better
                                                                                                       on exact and minute quantities of ingredients to
                                                                                                       taste just right, which is a highly important element       These conveyers are controlled by Advantech’s
                                                                                                       in food service market competition. Compound this           AMONet master module ADAM-5202 and motion
                                                                                                       with the reality that many food service manufactures        slave AMAX-2213/YS2 to support higher precise
                                                                                                       need their machines to churn out several different          motion control performance through high-speed
                                                                                                       types of instant food over the course of the day, and       serial communication technology. The ADAM-
                                                                                                       this means that operators are required to perform           5051S and ADAM-5056D are DI/O modules which
                                                                                                       time-consuming calibration and manual checking              integrates with the sensors, emergency stop button,
                                                                                                       each shift. Our customer needed a new system to             limited switched and push buttons together on one
                                                                                                       provide them with proprietary control, simple GUI,          module. For the recipes data output and control of
                                                                                                       and an overall faster and more accurate food service        the scales are powered by Advantech ADAM-5090
                                                                                                       process.                                                    modules, which guarantee deterministic I/O at 1
                                                                                                                                                                   ms. this feature guarantees control and response
                                                                                                                                                                   speed at I/O level so HMI software or operations of
                                                                                                                                                                   other application programs cannot affect I/O control

                                                                                                                                                                                                      RS-232                Limited Switches,            AMONet                     Conveyer Control
                                                                                                                                                                                                      Module                  Push Button                 Master
                                                                                                                                                                                                                          Emergency Stop Button          Module

37                                                                                                                                                                                                                                                                                                                             38
18            Metal Injection Molding
              Facility Management

 Introduction                                                                                      Project Requirements                                   Furthermore, with its compact size (255 x 152 x 59
                                                                                                                                                          mm), the UNO-2171 can be mounted easily in any
Metal injection molding is a relatively new process that takes advantage of several key            During the injection molding process, high tempered    space-constrained environment.                                The combination of Advantech’s hardware, software, and optical technologies in one product offering
technologies to produce molded metal parts of various properties. Although driven by the           steel molds are used to form parts into an uncured                                                                   provides an extremely robust, reliable, and affordable technology that can be easily used by non-technical
latest technologies in Industrial Automation, the molding process is very delicate, and if any     (green) state. In some cases, multi-cavity molds for                                                                 operators. Advantech’s UNO-2171 ensures hi-speed inspections (up to 60 per second), while maintaining
small pieces are left in the cavity after a part has been ejected, the mold can be severely        small, very complex orthodontic parts were being       Solution Description                                          100% accuracy. Our customers not only saves time and labor costs, but also prevents severe damage,
damaged during the next cycle. Therefore, our client was looking to develop an automatic           damaged by materials which remain in the mold                                                                        and avoids unnecessary down-time, which can often be more expensive and troubling than the mold
inspection system to monitor the molding process, and prevent severe damage. Advantech’s           cavities after ejection. Traditionally, the only way   The UNO-2171 is a Pentium M 1.4 GHz Embedded                  damage itself.
UNO-2171 was chosen as the control platform for the vision protection system, due to its           to make sure the cavities are always clear was to      Automation Computer with PC/104 Expansion, and
Pentium M-grade CPU, fanless architecture, rich I/O support, its USB 2.0, VGA, and LAN ports,      have the operator manually check the cavity after      the ADAM-6060 is an Ethernet-based 6-ch Isolated
and its overall superior industrial design.                                                        each mold has been ejected. However, this is a         Digital Input and 6-ch Relay Output module. The
                                                                                                   very time consuming and strenuous process for the      automatic inspection system was designed to
                                                                                                   operator, which frequently resulted in human error.    integrate UNO-2171, ADAM-6060 and a USB 2.0
                                                                                                   Not only would the mold and cavities be damaged,       CCD camera together. The UNO-2171 is integrated
                                                                                                   but operators were at risk due to the heated ovens     with ADAM-6060 through Ethernet port, and
                                                                                                   and dangerous machinery. Thus, our customer was        integrated with USB camera through USB 2.0 port.
                                                                                                   eager to find an automatic mold protection system
                                                                                                   to prevent damage to their equipment, moldings,        When the mold is open, the limit switch connected to
                                                                                                   and operators.                                         ADAM-6060 will trigger the camera to take a picture.
                                                                                                                                                          After image comparison, the ADAM-6060 relay
                                                                                                   Advantech’s UNO-2171 was chosen as the control         output will send a notice to the injection machine
                                                                                                   platform of the vision protection system. Monitoring   controller if there is anything inside the mold.
                                                                                                   cameras are connected via 2 x USB 2.0 ports,
                                                                                                   providing VGA output for any 1024 x 768 display.       After mold ejection, another sensor connected to
                                                                                                   Additionally, the LAN port was accessed for remote     ADAM-6060 will trigger the camera to take another
                                                                                                   setup, viewing & monitoring. In this fashion, two      picture. After image comparison, the ADAM-6060
                                                                                                   inspections occur, once before ejection and once       relay output will send a notice to the injection
                                                                                                   after. This complicated inspection process requires    machine controller if there are any foreign pieces
                                                                                                   high computing power which the PC-based UNO-           inside the mold.
                                                                                                   2171 (with Pentium M up to 1.4GHz) meets and
                                                                                                   exceeds. Moreover, UNO-2171’s industrial features,
                                                                                                   including its wide operating temperature (-10 ~
                                                                                                   60° C), and anti-vibration and anti-shock features
                                                                                                   makes the perfect choice for harsh environments.

                                                                                                                                                                                                                   USB                                  Obtains signal to trigger the camera
                                                                                                                                                                                                                                                         and output the inspection results

                                                                                                                                                                                   Mold                      Camera                                   Ethernet

                                                                                                                                                                                              Takes pictures used for
                                                                                                                                                                                              the inspection process
                                                                                                                                                                                                                                                                 Relay Output

39                                                                                                                                                                                                                                                                                                                            40
19             Textile Machine Systems
               Facility Management

 Introduction                                                                                      Project Requirements                                    the FPM-3060G can directly attach to the VGA port
                                                                                                                                                           and operate the working data on the ADAM-5550KW
 Textile manufacturers are constantly readjusting the textiles they create based on evolving       After many tough years, the textile industry has        to manage the pattern database and machine                 •The new system has removed unreliable moving parts, providing a complete fanless solution
 style trends. Patterns, thickness, materials, and the methods used for cutting them are
 always in a state of flux based on popular tastes. Traditionally, this involved factory-wide
                                                                                                   learned that survival relies on investing in new        information.                                               •Standard Programming Language
                                                                                                   equipment and technology. In the past, they relied
 paradigm changes, lengthy calibration adjustments, overhauls of machine equipment,                on two R&D teams (PLC and PC) to develop and            Modern textile patterns require high-speed cutting         •Standard Hard Drives offer additional space for more patterns
 and time-consuming operator training to get the output materials just right. Thanks to the        calibrate the machinery, which created a huge           with automatic data flow control. This is achieved         •Operators can edit patterns on the same machine without having to download them from other
 recent contributions of powerful pc-based machine technology; productivity, versatility, and      bottleneck, effecting both development time and         by taking advantage of the AMAX-2211 and AMAX-              machines, saving time and requiring only one operator
 consistency of patterns has all been heavily upgraded. Therefore, today’s textile manufactures
 are not only much better armed to deal with ever-changing style trends, but can also guarantee
                                                                                                   quality. Our customer was interested in adopting        2210 for the Niddle control of complex patterns,
                                                                                                                                                           and another AMAX-2210 to offer flexible silk feeding
                                                                                                                                                                                                                      •Advantech’s ADAM-5550KW Programmable Automation Controllers feature single standard
                                                                                                   proprietary controllers, but was turned off by the                                                                  programming and engineering tools to save time on developing applications (cross-language
 consistent, accurate, and high-quality textiles to their buyers.                                  high maintenance costs and the difficulty to maintain   control. All the limited switches and push buttons,         programming)
                                                                                                                                                           emergency stop buttons are managed by ADAM-
                                                                                                   the system (Ladder Diagram, C, VB…). Advantech
                                                                                                   stepped in and recommended a textile machine            5051S and ADAM-5056D DI/O modules.                         •Real-time features to fit market demands
                                                                                                   integrated with PC-based technology, which could                                                                   •Greater accuracy than manual measurements
                                                                                                   be easily maintained and operated, and run their
                                                                                                                                                           In the new system, the ADAM-5550KW
                                                                                                                                                           Programmable Automation Controllers incorporate
                                                                                                                                                                                                                      •Consumer friendly, accentuating safety and privacy (fully automatic)
                                                                                                   entire operation more efficiently. Utilizing a single
                                                                                                                                                           multi-domain functionality, common development             •Easily customized measurements for up-to-date market
                                                                                                   programming tool is one of the most important
                                                                                                                                                           platforms, open standard interfaces and distributed
                                                                                                   factors in saving time on development applications.
                                                                                                                                                           modular architectures.

                                                                                                                                                           Textile machine applications require highly stable
                                                                                                   Solution Description                                    operating systems to satisfy conditions such as
                                                                                                                                                           real-time functionality, handling system crashes and
                                                                                                   Traditionally textile machines have used proprietary    unpredictable system resets. Embedded operating
                                                                                                   technology and PC-based controllers to integrate        systems, such as Windows CE and Embedded XP
                                                                                                   product information to MES. This means that two         provide excellent support for PAC modules. Windows
                                                                                                   technologies were needed to maintain different          CE can meet real-time application requirements and
                                                                                                   systems, requiring more manpower and more time.         Embedded XP is a modularized version of Windows
                                                                                                                                                           XP With proper programming, control programs can
                                                                                                   The new generation of Programmable Automation
                                                                                                                                                           operate correctly, even if the system is under blue
                                                                                                   Controllers (ADAM-5550KW) combines a PC’s
                                                                                                                                                           screen status. Through Embedded XP’s SP2 EWF
                                                                                                   high computing power and easy operability with a
                                                                                                                                                           function, engineers have no fear of an OS crash by
                                                                                                   proprietary robustness. In this new system, ADAM-
                                                                                                                                                           an unexpected system reset, and no longer need
                                                                                                   5550KW works as the main controller with built-in
                                                                                                                                                           R&D teams to handle PC and proprietary systems
                                                                                                   HMI functionality through the VGA port, no longer
                                                                                                   requiring users to develop additional SCADA PC’s;

                                                                                                                                                                                                Limited Switches,          AMONet                  AMONet Master Module
                                                                                                                                                                                                  Push Buttons,             Master                   Limited Switches,
                                                                                                                                                                                              Emergency Stop Button        Module                      Push Buttons,
                                                                                                                                                                                                                                                   Emergency Stop Button

41                                                                                                                                                                                                                                                                                                                  42
20              RFID in US Supermarkets
                Facility Management

 Introduction                                                                                       Project Requirements                                    increase efficiencies of scale (i.e. receiving the right
                                                                                                                                                            numbers of goods from vendor at the right time,
 With many items coming in and going out every second, supermarkets need very accurate              Supermarkets need an accurate system for                many times).                                                     •Easy installation Embedded Controller
 methods of maintaining product inventory. One of the largest supermarket chains in the US
 uses barcode technology, which is a labor intensive scanning process. Though used by many
                                                                                                    maintaining product inventory which can be applied
                                                                                                                                                            Furthermore, the supermarket will incorporate a                  •Real-time Management System for stock updates
                                                                                                    to any physical item. Moreover, this system needs
 supermarkets, this process has difficulty keeping accurate inventory and shipping transaction      to include a personalized tag which can carry unique    supply chain smart label compliance concept,                     •Easy and quick shopping for consumer
 records. Our customer wanted to switch to a Radio Frequency Identification (RFID) system to        and detailed information about each product. The        working with its vendor to label all incoming                    •Cost-saving measures into Supermarket Management Operation
 increase their inventory control. Along with Advantech‘s Embedded Automation Computer, the
 system is setup with an RFID reader in the supply chain and lock gate to assist with inventory
                                                                                                    latest technology allows for the use of an embedded     inventory with RFID labels that will be received at
                                                                                                                                                            its warehouse. With this inventory being encoded
                                                                                                                                                                                                                             •With this new system, the supermarket is expecting to save over $1.3 million a year
                                                                                                    chip, which carries a unique radio ID tag. This chip
 tracking in their warehouse.                                                                       sends out a signal allowing it to communicate with      correctly, the supermarket can receive, identify and
                                                                                                    a reader device and other products embedded             updated its receipts faster, providing management
                                                                                                    with similar chips. This system is used to identify     with better visibility on its inventory levels.
                                                                                                    and track every item from the warehouse to the
                                                                                                                                                            As inventory is shipped and received between the
                                                                                                    supermarket shelves. Furthermore, this system
                                                                                                                                                            supermarket, the warehouse, and its vendor, this
                                                                                                    features a wide operating temperature, and shock
                                                                                                                                                            system can be utilized to record all sold-out goods
                                                                                                    and vibration protection for reliable use in harsh
                                                                                                                                                            and/or receipts to update inventory levels more
                                                                                                    warehouse environments.
                                                                                                                                                            accurately while, reducing labor, and minimizing
                                                                                                    Solution Description
                                                                                                    The RFID readers are setup with Advantech‘s UNO-
                                                                                                    2170 network processor and a printer server. All the
                                                                                                    transactions are interfaced directly to supermarket’s
                                                                                                    Warehouse Management System, and web services
                                                                                                    are utilized to move transactional information which
                                                                                                    includes receiving and shipping information for the
                                                                                                    primary and high volume transactions.

                                                                                                    By introducing this system into the Supermarket
                                                                                                    Management System with a primary focus on
                                                                                                    receiving and shipping, our customer will increase
                                                                                                    their inventory accuracy, reduce incorrect shipments
                                                                                                    from their vendors, reduce labor efforts, and


                                                                                                                                                                                                                       RFID Reader                                  RFID Tag


43                                                                                                                                                                                                                                                                                                                  44
Wiring Table

       Panasonic MINAS-A   Yaskawa SGDM   Mitsubishi MR-J2S   Oriental LIMO EZMC

 45                                                                                46

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