The Latest Transmission Controls for Utility Vehicles

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1 No /2016 Newsletter Editorial Volker Pape Dr. Martin Heuser Dear Readers, Impressive presentations and wonderful summer weather Viscom Technology Forum 2016 was a complete success. This was our first opportunity to welcome our customers in our new company building: Now we have more space available for customer training and system presentations. This expansion was a result of convincing technology: The S3088 ultra with the XM module has secured us a leading position in optical inspection. All indications point to expansion in the X-ray technology area, too: The X8068, and the new X8011-II PCB, are perfectly suited for the demands of the electronics industry. Top X-ray inspection results at high throughput. Best regards, Volker Pape Executive Board Viscom AG Dr. Martin Heuser Executive Board Viscom AG Inspection with 3D SPI and 3D AOI from Viscom at WABCO The Latest Transmission Controls for Utility Vehicles The firm Westinghouse Air Brake Company (WABCO) looks back on a long history in the United States, yet today is headquartered in the Belgian capital of Brussels. Its locations are distributed from the USA to Australia, India and Japan, as well as many other countries including Germany. As part of an ongoing development partnership since 2014, WABCO has realized a prototype line in stages at its Lindener Hafen location in Hanover, Germany, with the systems S3088 SPI and S3088 ultra from Viscom. Today s result: The false call rate could be consistently decreased and First Pass Yield (FPY) significantly increased. Among its other products, WABCO is known for its ABS systems. Electronic braking systems, transmission controls, air suspension systems and the associated peripherals, like compressors and air dryers these are the electronic items our customers seek from us, states Lars Schulze, test methodologist at WABCO. Customers include DAF Trucks, Daimler, MAN, Scania and Volvo, as well as ZF Friedrichshafen. In the Lower Saxony continued on page 2 Contents Technical Article Prototype Line at WABCO Page 1 3 Products 3D AOI from All Perspectives Page 4 Greater CCI Inspection Range Page 5 Viscom Remains a Strategic Supplier to Continental Page 5 Company Direct Wire to the Specialists Page 6 Viscom App Page 6 Grischa Wasmus Strengthening the European Sales Team Page 7 Review Technology Forum 2016 Page 7 Junge Wilde at Viscom Page 7

2 Technical Article continued from page 1 regiona l capital Hanover, WABCO engages around 2,600 employees, with about 250 of them in electronics production. Extremely high packaging density One very important product right now that is manufactured in the prototype line is a new, highly complex transmission electronic unit with around 450 components, to be used in utility vehicles as the core of the transmission control. Rüdiger Borges, lead process engineer at WABCO, comments: We introduced this transmission electronics unit in 2015; the space on these printed circuit boards available for electronic components is occupied at up to 95 percent. This is atypical in comparison to normal electronics manufacturing, where space requirements could be about 70 to 80 percent. Especially for this product, with its extremely high packaging density where sometimes not even the inspection system s angled camera reveals much of value, the 3D analysis is a great help. Everything is closely packed side by side, which is one good reason WABCO deploys the 3D AOI system S3088 ultra from Viscom in its prototype line. According to Borges, development increasingly leads toward smaller component types such as the QFN, on which the connections are no longer visible at all or with angled cameras, are visible only to a limited degree. Convincing features Among other things, the Viscom Uplink Process Analyzer (VUPA) enables the comparison between SPI data and AOI images Among WABCO s goals for the solder paste inspection (SPI) in the prototype line was to be able to entrust the employee occupied there with other tasks. This was very successfully realized with an S3088 SPI from Viscom. This system capabilities for automated data networking via the Quality Uplink and the verification station HARAN from Viscom were especially convincing. Yet another plus is the S3088 SPI 3D function: If the paste is looked at from above, only a surface is seen. But I never know, is this paste volume also high enough and is it sufficient to definitively reach the minimum volume? This is better perceived with a 3D inspection than with a 2D, explains Andreas Sommerfeld, process technician at WABCO. Efficient printing process The Viscom Quality Uplink also includes the Closed Loop between the solder paste inspection and the upstream stencil printer. Among its other functions, the SPI cyclically determines and transfers specific values to the printing process. This way, the X/Y offset can be automatically corrected, says Sommerfeld. Consequently, he and his colleagues can greatly extend the printer cleaning cycle. This saves both time and material. The employees at WABCO wanted to know with as much detail as possible when a defective printed circuit board actually needed to be taken out of the production line, for example, right after the printer because the SPI system indicates the paste is smeared or there is no paste at all. In these cases, assembling with components would be superfluous. This is especially worthwhile at WABCO, where certain products are not permitted to be repaired and there is no other option than to scrap them. If defective printed circuit boards are not needlessly assembled with components, costs and materials are saved. The earlier they can be sorted out, the better. This is where the S3088 SPI from Viscom makes a substantial contribution. Lead process engineer Rüdiger Borges, Wolfgang Herbig from Herbig Technologies and test methodologist Lars Schulze next to the S3088 SPI Instant information For the S3088 ultra, WABCO had stipulated a requirement for at least 80 percent FPY. Lars Schulze describes the advantag- 2

3 Technical Article es of automatic optical inspection (AOI) with 3D: For the presence inspection, no special cameras or adapted illumination are needed; neither are fine adjustments for the different components or printed circuit board colors. With the 3D raster, whether or not the component is there is immediately apparent. Now we have direct measurements, can record frequencies and statistically calculate stability. As one example, analysis of the last 50 printed circuit boards instantly informs the operator where tolerance ranges have been exceeded; changes in the process can be made based on these indexes, says Schulze. This is one of the ways 3D analysis with the Viscom AOI system ensures fast, dependable results in detecting component fluctuations, coplanarity or other defects. Numerous inspection patterns were fundamentally streamlined because unwieldy linked analysis steps could be omitted. Component body detection is greatly improved by the 3D analysis, so lifted leads and other defects are easier to find. The 80 percent FPY has long since been achieved. Even 90 percent FPY has become a norm rather than an exception. Just as with the SPI inspection stage, now the employee who formerly stood at the AOI system is primarily occupied with the ICT (In-Circuit Test) system. Optimization on demand Viscom also quickly and efficiently realizes individual requests for optimizing the prototype line. Now defective printed circuit boards on the S3088 SPI can be removed relatively quickly by just opening the hood. Previously, the machine had to be shut down and started up again. Also within the scope of paste inspection, Planned Engineering Innovation Center at WABCO in Hanover marking to indicate the potential necessity for an X-ray inspection has been automated. Another example of an individual solution at WABCO is the manual barcode entry on the SPI system. Tests guarantee long service life At the WABCO location in Hanover, the long-term stability of electronic assemblies is also tested. If, for example, 50 percent of the paste is missing on a resistor, it is not evident to the eye because everything is cleanly soldered. But it is unlikely these printed circuit boards would ever withstand the load test through which WABCO checks mechanical resiliency for a desired service life of from ten to 15 years. In this test, the electronics must be able to endure temperature fluctuations from -40 C to +150 C because, for example, they are installed tightly within a transmission. Internal processes according to Six Sigma + Lean The worldwide transport of goods and use of public transportation means are both trends with a very promising future potential. Rising demands on safety and environmental aspects are essential challenges. As a supplier of intelligent solutions for the utility vehicle industry, WABCO is right in the middle of these exciting developments. An intelligently networked inspection of the electronic products is an integral component in these developments. The WABCO quality goals are grounded in the Six Sigma + Lean philosophy. Specially trained internal employees actively ensure these goals are met. This is why we also have our training center here in Hanover, which is officially open to other companies as well, according to Borges. Six Sigma + Lean is strictly integrated into practice at WABCO; correspondingly, defect detection and process optimization are addressed as an indispensable aspect of this focus. Sustainable handling of resources also plays a very important role here. Viscom Download The text is truncated. Here you will find a more detailed article about the subject: 3

4 Products A Major Step Ahead with Viscom 360View Extraordinarily Realistic 3D AOI from All Perspectives Under the name 360View, Viscom has developed an advanced software to enable highly precise 3D image acquisition in the automatic optical inspection (AOI) area. The representation of side views of electronic components, a pronounced weak point on many 3D systems with orthogonal cameras, can now be displayed in realistic detail with the angled cameras of the Viscom camera modules and 360View. No lateral inaccuracies Thanks to 360View, a great deal more than just height information is available for the display of component sides for 3D AOI. The operator is offered a correctly textured image with no lateral inaccuracies from all the freely selectable viewing angles. This advancement will be available for the following inspection systems: the S3088 line, S6056 and X7056 (AOXI model), with a new vvision software version. Peter Krippner, Vice President of Serial Products at Viscom AG, states: With 360View, we are a major step ahead of other competitors and will continue to steadily pursue 3D as an effective AOI technology. High-quality approach This improvement is possible because Viscom has relied on a high-quality approach in image acquisition technology for decades. Many conventional AOI systems work with just one orthogonal camera. To build a 3D reconstruction, projectors cast a fringe pattern on the inspected object one after the other from With 360View, components, leads and defects such as tombstoning are visible from any viewing angle clearly and without deficiencies an angled position; these patterns are then available via the camera as information for calculating the spatial images. It is not possible to realize the same quality as the 360View with this approach, because it lacks the requisite data for angled views. The texture information from such a standard image acquisition must be drawn down over steep component edges like a waterfall. Reliable defect classification In comparison, the Viscom camera modules integrate an optional four or eight angled view cameras in addition to the orthogonal cameras, and only one projector is needed. This results not only in a terrific advantage in image acquisition speed, but also in true-to-life accuracy for the display of individual components. In practice, for example, it is possible to look beneath the bent leads of a QFP with 360View. Only with the data from 360View, the operator receives a 3D representation with which a reliable defect classification can be made, so product quality can be positively ensured. Have we sparked your interest? Then speak with us at electronica in Hall A1, booth No. 217: Do not hesitate to contact us with any questions or for additional information. We look forward to seeing you! 4

5 Products HighDensity Module for Silicone Varnish and Very Thin Coatings Viscom Enables Greater CCI Inspection Range There are two options for the orthogonal camera technology of the well-proven inspection system S3088 CCI from Viscom: While the integrated standard module has more than fulfilled most of the demands for a long time, with the HighDensity module, an additional configuration possibility is now available. This offering reflects the latest developments in electronics production. The HighDensity module is especially recommended when nano or plasma coatings need inspection. It is also ready to inspect the extremely temperature resistant silicone-based varnishes. Coatings of this type are used, for example, to make smartphones resistant to moisture. Missing varnish layer displayed in black Extended field of application Among its other features, the HighDensity module is distinguished by special high-power LEDs which are attached around the camera. Their ultraviolet light (black light) with special wavelengths clearly extends the field of application of the S3088 CCI and provides optimum illumination even for weakly fluorescing Conspicuous bubble in the lead area varnish types. Peter Krippner, Vice President of Serial Products at Viscom AG: With this configuration of the S3088 CCI, the customer has absolute versatility. All current inspection tasks can be reliably accomplished. Just as with the orthogonal standard, the HighDensity module can be additionally equipped with four or eight angled cameras. With this configuration, the quality of the coating layer can also be inspected on the sides of the components with no further effort. Fluorescing varnish layer In conformal coating inspection (CCI), generally special LEDs illuminate varnish mixed with particles that fluoresce under UV. The varnish layer typically fluoresces in blue under this excitation. With the right frequency adjustments, all typical defect sites are reliably detected. The Viscom inspection system S3088 CCI finds defects such as air bubbles, contamination or missing coatings dependably and ensures the guaranteed high quality of the conformal coating on the electronic assemblies. Successful Selection after a Comprehensive Evaluation Viscom Remains a Strategic Supplier to Continental in the AOI Area Viscom AG has successfully proven itself in a benchmark for automatic optical inspection (AOI) and remains the preferred supplier to the Automotive Group of the Continental Corporation for the important printed circuit board inspection area. The official notification of the successful selection came at the end of April at the SMT Hybrid Packaging trade fair. Intensive test in Sibiu Viscom is listed as worldwide AOI supplier for Continental. This news resulted from a comprehensive evaluation involving several competitors which had taken place in summer During the intensive eightweek test at the Continental plant in Sibiu (Romania), Viscom was able to convincingly prove its technology. Further tests and an audit at Viscom headquarters in Hanover-Badenstedt completed the benchmark activities. Peter Krippner, Vice President of Serial Products at Viscom AG: We are extremely pleased that Continental acknowledges our claims to technological leadership and customer orientation. All the Viscom employees stand behind this concept with their full commitment. Viscom sees this as further incentive to convince with innovative peak technology in the future as well. 5

6 Company Direct Wire to the Viscom Specialists Second Contact Partner on the Applications Hotline Versatility with Smartphone and Tablet Mobile Real-Time Access to Production and Quality When someone called the Viscom Applications Hotline, normally Horst Hildebrandt, one of the specialists for standard products (SP) at Viscom, picked up at the other end. With Heiko Straaten, now he is joined by a second contact person to deliver expert assistance across Europe. Both SP applicators find quick solutions when effects requiring knowledge beyond normal production processes occur with Viscom inspection systems on the production line. To avoid configurations that disrupt functions from the very start and to receive continual consultation, the fee-based Viscom Premium Applications and Software Hotline is recommended. Covering all requests The Applications Hotline is a seamless supplement to the Viscom Service Hotline. The Service Hotline primarily offers support in case of machine malfunctions and is concerned with questions about maintenance and repair of the inspection systems. More information about the Applications and Service offers is available on the Viscom website. From left: Christoph Mroncz, Horst Hildebrandt, Jens Czaja, Heiko Straaten and Benjamin Kage Have all the essential information about the inspection process at hand any time and call it up from anywhere this will be possible very soon with the new Viscom App. With the upcoming vvision Release 2.4, it will be ready to run on today s widespread operating systems Android and ios. Its numerous features bring significant added value to quality assurance while increasing transparency in internal company coordination and logistics. Clearly structured production With the Viscom App, key variables like throughput and performance are controlled with the utmost convenience. The data is made available on a local Viscom server. After logging in, the user receives an overview of the entire production of his company. A few clicks lead to the product selection. This overview can be limited not only spatially, but also temporally. The smart mobile application provides data for each vvision inspection system from Viscom. This includes the number of inspected electronic assemblies, real defects detected, and more. A wide range of differentiated information, like first pass yield, PPM rate (parts per million) and DPMO rate (defects per million opportunities), is available in an instant. Values and their statistical correlations are displayed in closer detail on various charts, such as a Pareto diagram for defects sorted according to their frequency. This offers employees from line supervisors to production managers, quality and business management too the opportunity to view relevant processes and the versatility to develop on-the-go solutions anytime, anywhere. Fast assignment of electronic assemblies Yet another practical tool from the Viscom App is the printed circuit board check with a smartphone camera. With it, the operator can scan the barcode of a printed circuit board. The mobile application promptly displays inspection results and defects that have already been verified. As another example, a returned product with its entire history can be precisely identified immediately. The advantages are right at hand. The smartphone, by now an everyday companion, becomes a future-oriented tool in the sense of Industrie 4.0, Smart Factory and Big Data handling when combined with the Viscom App. 6

7 Strengthening the European Sales Team Grischa Wasmus Joins Viscom Sales customer service at Viscom has been reinforced. Grischa Wasmus, from Hanover, Germany, will take an active role in the sales of inspection systems in Europe. The 37-year-old studied electrical engineering in Hanover. After completing his studies, he gathered a wide range of valuable experiences at a well-known electronics services provider. In this function, Grischa Wasmus was involved with the areas of production automation and Industrie 4.0, optimizing the quality, transparency and efficiency in internal technical processes. Later, as key accounts manager, he was in direct contact with important clients of the service provider. Grischa Wasmus looks forward to his new challenges. Among other aspects of his position, Viscom s technological strengths and international alignment were convincing. He comments on his new function: Because of my occupation with an EMS service provider, I am completely familiar with electronics production. This is a benefit to bring to my assignments and thus, my customers. Technology Forum 2016 Concept of the Event Further Improved The participants could choose from a wider selection this year numerous informative technical presentations and workshops, as well as new elements such as tutorials and exclusive conversations with specialists (Meet the Experts). Another first for this event was, it was hosted in the facilities of the new Viscom building on Carl-Buderus-Straße 6. In the keynote speech, automobile designer Murat Günak illuminated the future of mobility. The highlight of the evening get-together was comedian Benjamin Tomkins. Building on the positive experiences of the past, this had been a reason for Viscom to further improve and expand the concept of the event so it was Save the date Viscom Technology Forum June 21 22, 2017 more closely attuned to the needs of the different guests. The mixture of application, research, theory and a noteworthy look over the horizon proved itself yet again. We are very pleased with the resonance again this year and are already thinking ahead to Technology Forum 2017, as Volker Pape, Viscom Executive Board, summed up the event. 1st Women s Team of HSG Hanover-Badenstedt Junge Wilde Presented at Viscom As one of the long-time supporters of the Hanover-Badenstedt Handball Association (HSG), Viscom AG invited the 1st Women s Team to a public presentation. Along with the local press, other sponsors of the handball team Junge Wilde (Young Wild Ones) were also present. The team had previously qualified for the 2nd Federal League and were arming themselves for the challenging 2016/2017 season. The venue for presentation of the team on August 19 was the foyer of the new Viscom company building in Hanover-Badenstedt. Volker Pape, Executive Board, Viscom AG, and HSG Manager Peter Kretzschmar welcomed the guests. Next, press and public announcer of the HSG, Uwe Pichlmeier, first introduced the handball teams of the Badenstedt TVB and BSV Associations represented by the abbreviation HSG and then the individual members of the 1st Women s team that were present. He stressed, We no longer build for others. That topic is over. Now 7 Volker Pape (center) and HSG trainer Florian Marotzke (left) with the members of the 1st Women s Team of HSG Hanover-Badenstedt we are building for ourselves. We want to attract talent.

8 Imprint Publisher: Viscom AG Carl-Buderus-Straße Hanover Germany Tel.: Fax: info@viscom.com Editor: Olaf Szarlan Tel.: Graphics and Layout: Gaby Reglitz #Viscom_NL_36_10/2016 _EN