Automatic Optical Inspection AOI

Automatic optical inspection (AOI) is a process in electronics production and is used for quality control of electronic components. In AOI, optical systems and cameras are used to check products, especially printed circuit boards (PCBs), for faults and defects. AOI systems can quickly and precisely check whether the products meet the specified quality standards. In this way, AOI helps to ensure quality and efficiency in manufacturing processes by eliminating rejects and rework.

How does an AOI system work?

With high-resolution cameras and software, the products to be inspected are analyzed during or at the end of the production process. First, an image is taken. This is then checked using software. Reference images are compared with the image taken. Are all solder joints in the correct position? Are all components present and in the correct position? Are there any other defects?  Any errors and defects are noted by the software and the parts are sorted out in a further step.

In production lines, the AOI system can be used to quickly and accurately check large quantities of electronic components. The early detection of faults and defects on components and PCBs reduces rework and rejects, thus minimizing production costs and ensuring the safety of the components we rely on every day.
In electronics production, printed circuit boards are primarily inspected using AOI systems. Safety-critical components can thus comply with the specified standards, for example in the automotive industry, aviation or medical technology.
 

End of line test (EOL)

An end of line test (EOL test) is a process that is carried out at the end of a production cycle to check the quality and functionality of electronic components or printed circuit boards. The products are contacted and tested either via test points or the device connector.
Performing the EOL test at the end of the production line offers several advantages. Errors that occur during the production process can be detected and quality can be guaranteed.
During the EOL test, electronic components, PCBs or entire PCB panels are contacted at predefined test points and checked for faults. This includes checking for assembly, press-fit or soldering faults as well as detecting short circuits, interruptions and defects. Product quality is particularly important in sectors such as the automotive industry, energy supply, healthcare, aviation, lighting and the Internet of Things (IoT).

 Would you like to know how we integrate EOL tests into our systems?
You can find out more here!

Functional test (FCT)

Today, electronic components are an essential part of various products in almost every industry. They are used in areas such as the automotive industry, energy industry, medical technology, consumer goods industry, lighting industry, industrial goods and the Internet of Things (IoT). Faulty components can have significant consequences and cause enormous costs for the manufacturer. It is therefore crucial to carefully test electronic components, PCBs and PCB panels in order to ensure quality and increase efficiency.

During the functional test (FCT), the units to be tested are checked to see whether they can perform the required functions correctly. This test is carried out in an automated line and covers various aspects:

- Operation of buttons, controls, switches and other user interfaces to 
- Check functionality.
- Simulation of environmental influences such as extreme temperatures or humidity, while simultaneously testing the function of the units.
- Exposing the units to changes in the electrical inputs such as voltage interruptions and checking the reaction to undesirable influences such as switching off in the event of overvoltage.
- Testing the processing of digital input signals.
- Checking sensors, for example through NFC.
 

In Circuit Test (ICT)

In electronics manufacturing, product quality is paramount, as faulty components can have a significant impact and lead to significant costs. Electronic components are essential in various industries, whether in the automotive industry, energy industry, medical technology, aviation, lighting industry or the Internet of Things (IoT).
During in-circuit testing (ICT), electronic components, PCBs or entire PCB panels are checked for assembly, press-fit or soldering errors. Predefined test points are contacted and tested with spring-loaded contact pins. This makes it possible to detect and sort out short circuits, interruptions and defects during the production process. This reduces the cost of rejects, as the parts can be sorted out or repaired immediately before they are sent for further processing.
 

Climate test, run-in test, burn-in-test 

There are various reasons why components and PCBs are tested under different climatic conditions. Climate tests or burn-in tests for PCBs, for example, ensure that they function reliably under specific environmental conditions such as heat, cold and humidity. These stress tests are carried out in particular on safety-relevant components for applications in the automotive, aerospace and medical technology industries.
During the burn-in test, also known as climate test, components or electronic assemblies are exposed to a climate profile with changes between cold and high temperature ranges as well as humidity. During this phase, they are monitored by a test system to ensure that they meet the strict requirements for reliability and stability. In this way, the stress to which the component could be exposed during its entire life cycle can be simulated, thus avoiding potential problems and failures during subsequent operation.

Would you like to know how we integrate run-in tests into our systems? 
You can find out more here!
 

Mechanical engineering

Nowadays, there is hardly an industry that can function entirely without machines in one form or another. Mechanical engineering is one of the most export-intensive and important sectors of the German economy. No matter what products you think of today, almost everywhere there are machines behind them, that manufacture these products. Whether for the manufacture of technical products, for the extraction of raw materials, for food, medical technology or vehicles. These machines are developed, designed and produced in mechanical engineering companies. Mechanical engineering covers machines of all types, sizes and sectors.

Assembly line

An assembly line is a production system that is used for the time-saving and efficient manufactureing of products. It consists of coordinated assembly activities such as joining, handling or adjusting. Assembly lines can be operated in both - flow production and cycle assembly, whereby the sequence of assembly steps and the cycle time are precisely coordinated.

Types of assembly lines

Linear transfer systems: These systems transport workpieces in a straight line from one station to the next.
Rotary transfer systems: Here, the workpieces are moved from station to station on a rotating table.
Robot cells: These cells integrate robots to perform specific assembly steps.
Customized special solutions: Customized systems that are specifically designed to meet the requirements of a particular product or process.

Advantages of modern assembly lines

High degree of automation: Modern assembly lines use advanced technologies to automate and optimize production.
Short throughput times: Products are completed faster thanks to the efficient coordination of assembly steps.
Consistent quality standard: Automated processes ensure consistent quality.
Sustainability and efficiency: Optimized processes and the use of innovative technologies make production sustainable and efficient.
 

Degree of automation

Fully automated assembly lines: On these lines, components are assembled exclusively by machines. The technologies used include hydraulic presses, innovative screwdriving systems and systems for riveting, sealing and testing technology. Robots play a central role in maximizing the efficiency and precision of assembly.
Semi-automated assembly lines: In these systems, people and machines work together to take advantage of both worlds.
Assembly lines are an essential part of modern production processes. They enable the efficient and time-saving manufacture of products by precisely coordinating and automating assembly steps. Turnkey assembly lines offer the highest degree of automation and maximum efficiency, tailored to the respective specific requirements and products.
 

PCB test / Printed circuit board test

Printed circuit boards play a significant role in electronic devices and are therefore often used in safety-relevant applications. Because of this importance, it is of the utmost importance to ensure the quality of the PCBs. This is where the printed circuit board test or PCB test comes into play, which is responsible for this quality check. It checks the PCBs for production errors and functionality after assembly.
In the function-independent PCB test, errors on the PCB are checked independently of the application context, for example by measuring resistance to detect soldering errors.
For the functional test, the PCB is contacted with test probes at specific test points. As PCBs can have different assemblies and properties, a special test adapter with the corresponding test points is required to test the PCB effectively. The functionality of the PCB is then checked using a test system. This includes, for example, testing the transmission of digital signals or detecting voltage interruptions.
 

Test automation

Nowadays, modern automation solutions and systems consist to a large part of automated testing, which ensures that faults and defects are detected, minimized or resolved during the production process. For example, an in-circuit test (ICT), a function test (FKT) or an EOL -  end-of-line test (at the end of a production process) is integrated into systems.
 

Customized mechanical engineering

Customized mechanical engineering is a branch of mechanical engineering, whereby the transition is fluid. 
Special machine construction companies specialize in building automated machines and systems that cannot be covered by standard solutions. In custom mechanical engineering, individual automation solutions are created that are adapted to the needs of the customer and designed and manufactured for the specific product and production characteristics. The differences to standard solutions often lie in even faster production, in the processing and handling of very special workpieces or in unusual test specifications.
The customizability of the systems is the main distinguishing feature of special machine construction compared to normal machine construction.
 

Test adapter / Test fixture

Test fixtures or test adapters for printed circuit boards are used in fully automated industrial systems, but are also used in manual applications.
Test adapters check the functionality of printed circuit boards and electronic components, for example, and thus ensure the quality of the electronic end products. Buttons and rotary actuators can be tested, audio tests can be carried out, a load simulation can be performed, connectors can be contacted or, if a camera is integrated, visual tests can also be carried out. 
Testing electronic components during the production process eliminates the need for costly and time-consuming rework. Some suppliers are able to equip test lines and test cells with new test adapters so that new products and different components and PCBs can be tested on one test line/cell. These test adapters are then usually customized to the respective component or PCB and matched to each other. The test adapters can be used for in-circuit tests, functional tests and for programming the device.
 

Would you like to know more about our test and inspection adapters?
Find out more here!