Verifying a printed circuit board manufacturing process prior to electrical intercoupling

Apparatus and method for performing a verification buy-off operation during an assembly manufacturing process, such as during printed circuit board (PCB) manufacturing. A processing device is configured to establish contact between a probe assembly and a first component of an assembly having a plurality of components loaded in predetermined positions but not yet electrically intercoupled, and to receive from the probe assembly a component value associated with the first component. Preferably, the processing device further determines whether the received component value is within a predetermined specification. The processing device preferably directs a user via a graphical user interface (GUI) to manipulate the probe assembly to a position proximate the first component. The GUI preferably provides a graphical representation of the assembly and a marker that identifies the location of the first component thereon. All of the components of the assembly are preferably verified individually prior to a full production run.

BACKGROUND

Assembly manufacturing processes often undergo a verification (buy-off) operation to verify machinery setup, such as after a conversion from the manufacture of one type of assembly to another. The buy-off operation may help to reduce costly errors from being introduced into a full production run.

SUMMARY

Embodiments of the present invention are generally directed to an apparatus and method for performing a verification (buy-off) operation in an assembly manufacturing process, such as during printed circuit board (PCB) manufacturing.

In accordance with various embodiments, a processing device is configured to establish contact between the probe assembly and a first component of an assembly having a plurality of components loaded in predetermined positions but not yet electrically intercoupled, and to receive from the probe assembly a component value associated with the first component.

DETAILED DESCRIPTION

FIG. 1provides a top plan view of a data storage device100. The device100is provided to show an exemplary application in which various embodiments of the present invention may be utilized. It will be understood, however, that the claimed invention is not limited to the exemplary embodiments disclosed herein.

The device100includes a housing102formed from a base deck104and top cover106. An internally disposed spindle motor108is configured to rotate a number of storage media110. A head stack assembly114preferably rotates through application of current to a voice coil motor (VCM)116. Controlled operation of the VCM116aligns an array of transducers112with tracks (not shown) defined on the media surface to store and retrieve data, respectively.

A flex circuit assembly118provides electrical communication paths between the actuator114and device control electronics on an externally disposed printed circuit board (PCB)120. The PCB120preferably provides various control circuitry and routines enabling the functioning and operation of the various components of the device100shown inFIG. 1.

The PCB120is preferably produced en masse in an automated manufacturing process in which many hundreds or thousands of nominally identical printed circuit boards may be produced in a relatively short amount of time using automated machinery. When a new PCB is designed, it may be with the assistance of a computer aided design, or CAD program. Thus, a CAD file specifying the layout of the PCB120may generated and available for use. It is further contemplated that an electronic bill of materials (BOM) specifying the values, types, and tolerance of each of the electronic components of the PCB120may also be generated and available for use.

FIG. 2provides a generalized block diagram for a system200preferably configured to perform a verification (buy-off) operation during a manufacturing process201used to manufacture a population of assemblies, such as but not limited to PCBs as exemplified at120inFIG. 1. Preferably, the buy-off operation verifies the configuration steps utilized to set up the manufacturing process201in preparation for one or more production runs; for example, in the context of a PCB manufacturing process the buy-off operation preferably verifies automated machinery settings, component loader configurations, installation tooling setups, and so on.

The system200ofFIG. 2preferably comprises a processing device202coupled to an electronic probe assembly204. The processing device202is preferably connected to the probe assembly204via an electronic data bus206for command and data transfers using a suitable communication protocol.

As explained below, the processing device202preferably operates to establish contact between the probe assembly204and a first component of an assembly210(such as a PCB) comprising a plurality of components loaded in predetermined positions but not yet electrically intercoupled, and to receive from the probe assembly a component value associated with the first component.

The processing device202can take any number of desired forms, such as but not limited to a commercially available personal computer, a laptop, a handheld computing device, a special purpose machine controlled via electronic hardware or software, etc. The probe assembly204can also take any number of forms, such as but not limited to a multi-meter, a resistance, capacitance, and inductance (RCL) meter, a custom built probe assembly designed to test specific types of electronic components or integrated circuitry, etc.

The probe assembly204can further be fully automated with one or more articulating robotic arms and multi-axis positional feedback (e.g., optical) sensing, or can be manually or semi-manually operated by a user. The data bus206can take any number of desired forms, such as but not limited to a serial connection, a parallel connection, an RS232 connection, a wireless connection such as Bluetooth, or a data bus designed specifically to meet the needs of the system200.

FIG. 3shows an embodiment of the system ofFIG. 2in greater detail. The system inFIG. 3is numerically denoted at300and is specially configured to perform a buy-off operation for a test-run PCB210generated from a PCB manufacturing process. As explained below, the PCB210under test is preferably fully populated with associated components by the manufacturing process, but without the components being electrically intercoupled (e.g., through the application of a solder reflow operation, etc.).

InFIG. 3, the processing device202is characterized as a personal computer, and preferably includes a graphical user interface (GUI). The graphical user interface is preferably provided via a display device302that may also be touch-sensitive. In other embodiments, other input devices such as a keyboard304may also be used for user I/O operations. The data bus206ofFIG. 2is contemplated inFIG. 3as comprising an RS232 connection. The probe assembly204ofFIG. 2is contemplated inFIG. 3as comprising a resistance, capacitance and inductance (RCL) meter312to test circuit components. The RCL meter312can be any of a number of readily commercially available units with appropriate resolution and accuracy characteristics and host interface features for the system requirements.

The probe assembly204further preferably comprises one or more component probes such as represented at314. The probe(s)314preferably interconnect the RCL meter312with the PCB210being tested. Other probe configurations, including a plurality of different types of probes, can be used as desired.

As shown in the simplified illustration ofFIG. 3, the PCB210preferably provides mounting locations for multiple components such as resistors320, a capacitor322, an inductor324, and an integrated circuit chip326. Although only a limited number of exemplary components are shown, it will be understood that other printed circuit boards may have many components of various sizes, values, tolerances, pin-out configurations and other specified characteristics.FIG. 3Ashows the PCB210prior to the loading of the components inFIG. 3to illustrate exemplary mounting locations327. It is contemplated that an electronic bill of materials (BOM) and at least one CAD file are available for the PCB210, although such are not necessarily required for operation by the system300.

FIG. 4provides a generalized representation of a graphical user interface (GUI) preferably used with the system ofFIG. 3, characterized as a display (screen shot)400provided on the display device302. It will be understood that the screen shot400ofFIG. 4is merely exemplary, and a number of possible variations thereof can be used with the system described herein. The screen shot400is preferably produced on the device302ofFIG. 3via execution of Microsoft Windows® based programming by the processing device202.

The screen shot400is preferably divided into sections adapted to convey various types of information to a user. Window402graphically depicts the full layout of the printed circuit board being tested, so that various electronic components, integrated circuits, and connectors on the board are depicted graphically substantially in the correct location. This information may be derived from the aforementioned CAD file and/or electronic bill of materials.

The printed circuit board is subdivided as shown by the dashed lines in the layout window402. A single section can be highlighted that corresponds to the section of the printed circuit board currently under evaluation. A reticule410is provided to specify a particular component being tested out of all of the components on the print circuit board. To further aid a user of the system, a magnified layout window420is also preferably provided. The magnified layout window420preferably corresponds to the highlighted or active section of the full layout window402. As desired, real-time images of the PCB under evaluation can additionally or alternatively be displayed.

InFIG. 4, the reticule410is shown highlighting the same component in both the full layout window402and the magnified layout window420. It is contemplated that the reticule410is automatically advanced by the system to each of the components on the printed circuit board in turn, although the reticule410can also, or alternatively, be manually advanced by the user via the GUI interface (e.g., a mouse, keystrokes, etc.).

A status window430preferably shows an identifier, such as a label or name, of the component currently being tested. The results of a current test operation can also be displayed, as well as additional user prompts. A statistics window440is also preferably provided with multiple tabs enabling the user to retrieve various information on the condition of the board and buy-off process. The statistics window440also preferably provides information relating to the number of components on the circuit board that have passed, the number that have failed, how many are remaining, and how many components are missing.

The user preferably uses the probe assembly204and the GUI to proceed through the verification of the printed circuit board under consideration. Preferably, the various components are physically loaded onto the printed circuit board in accordance with the newly setup manufacturing process, but the loaded PCB is not subjected to a reflow soldering or other process normally applied to complete the various electrical interconnections. As desired, various components can be temporarily affixed onto the printed circuit board through the application of adhesives, tapes, or other mechanical fastening devices and/or materials. Intervening insulators or other materials can also be placed as desired to ensure electrical isolation of various components for the verification process.

Evaluating a loaded but not yet fully interconnected assembly in this manner preferably allows for component evaluation on an individual or subgroup basis. For example, using this approach may allow the characterization of individual impedance values for components (e.g., resistors, capacitors, etc.) that are normally connected in parallel (such as by conductive pathway329inFIG. 3A), thereby reducing the risk that erroneously valued components have been installed in such locations. Similarly, chips or other devices (or subgroups, thereof) that cannot necessarily be individually characterized once permanently interconnected with the PCB can be isolated and separately evaluated.

In this way, the buy-off operation preferably verifies that an assembly, such as a PCB loaded with components as specified by a CAD file and/or a BOM, has been formed properly by the manufacturing process prior to initiation of a large production run.

FIG. 5sets forth a generalized flow chart for a VERIFICATION PROCESS routine500, generally illustrative of steps carried out in accordance with various embodiments of the present invention. The routine500is preferably carried out using the systems previously described herein to verify a PCB manufacturing process, although such is not limiting.

At step510, information relating to the assembly under evaluation (in this case the exemplary PCB210ofFIG. 3) is initially provided to a processing device (such as the device202inFIGS. 2 and 3). Preferably, the information comprises component location data, an electronic bill of materials, and a printed circuit board diagram from an associated CAD. Those skilled in the art will recognize that component location data may be derived from the CAD file or separately generated.

A full component check according to the information provided during step510next preferably commences at step512. As discussed above, this preferably involves a sequential evaluation of each component in turn. While various embodiments contemplate some measure of user intervention during the evaluation process, it will be appreciated that steps512and following can alternatively be fully automated, as desired.

The routine preferably distinguishes among various different types of components and provides suitable verification for each. Thus, a determination is preferably made at decision step514as to whether the particular component currently being verified is a resistor, capacitor, or inductor. If so, the method preferably proceeds to step516where the user is prompted to characterize the associated component. This is preferably carried out via the GUI such as by a text message, an audio cue, or by other means.

At step518, the user or operator preferably measures the value of the component using the probe assembly. In some embodiments, the user couples the RCL meter312to the component being tested via one or more of the probes314, and the RCL meter determines an associated value of the component. The RCL is preferably auto-ranging so as to automatically measure ohms for resistance, farads for capacitance, and henrys for inductance in the appropriate ranges.

As has been described, both the location and the desired value and tolerance for the component will have been previously specified by the CAD file and the bill of materials. Therefore, step522preferably determines whether or not the value measured at step520is out of limit (e.g., beyond a selected threshold value T, etc.). If the value is out of limit, at step524an indication of such is indicated via the GUI. The user is preferably prompted at step526to re-measure the component, and the newly acquired value is stored at step528. Preferably, the probe assembly electronically communicates the value obtained by the measurement to the processing device during this step. In this manner, the user is not required to note or transcribe any values which could lead to errors in the testing.

Returning to decision step514, in the event that the component being tested is not a resistor, capacitor, inductor, a different branch of the routine is preferably utilized. In some embodiments, the user is directed to carry out a visual scan of the component, step530. During this step, the user verifies whether the component physically located on the board is the proper component for the circuit, as specified in the CAD file or electronic BOM. The user may refer to the GUI for such information, as desired. Preferably, the user also verifies the component being tested has the same physical shape and pinout as the component specified by the CAD file/BOM.

At step532, the user provides input into the processing device indicating whether or not the visually checked component passes or fails. In one embodiment, the user may use the input device304to communicate with the processing device202, as shown inFIG. 3. The user may be prompted to provide such input as “correct,” “missing,” “wrong orientation,” “misalignment,” or “other” in order to aid the data collection at this step. Thus, even for components that are not easily testable by electronic meters, a user will be able to track the correct placement, insertion, and orientation of the device.

WhileFIG. 5shows substantially visual verification of non-passive components, it will be appreciated that in other embodiments, the probe assembly can be configured to carry out any number of appropriate electrical signal characterizations, such as functional testing, memory data accesses, application of drive current, etc. with the associated component.

Following the testing of the specified component, whether visually or using a probe assembly, a determination is made at step534as to whether all components have been checked and measured. If so, then the routine500ends. Otherwise, the next component is selected at step536and the foregoing steps are repeated until all components have been verified.

At the conclusion of the routine500, a report is preferably produced to summarize the results of the verification process. The report can contain statistics related to the buy-off verification operation, as well as information regarding in specific failed components. The report can be used to enact any adjustments or corrections to the manufacturing setup as required to correct the deficiencies (if any) noted in the report. As desired, a new assembly can be generated from the updated process setup and the routine500can be carried out to verify the new manufacturing settings.

The results of the routine500can also be displayed graphically such as via the GUI. For example, a graphical overlay can be provided onto the displayed graphical representation of the PCB, with different colors, shapes and/or other markers used to highlight various status modes for the various components (e.g., green for pass, red for wrong component installed, etc.). Historical data can also be saved and evaluated for long term trend detection, analysis and process improvement efforts.

It will now be appreciated that the various embodiments of the present invention as described herein are well adapted to attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims.