Abstract:
A breakaway RFID tag is configured such that it comprises part of a Printed Circuit Board Assembly (PCB). Thus, the breakaway RFID tag can be used to track the PCB as it migrates through a manufacturing process. In one embodiment, the RFID tag can be assembled first and then used to track the PCB as it is populated with components and installed into larger assemblies and ultimately into the end device. Once the PCB is installed into a larger assembly or the end device, the breakaway RFID tag is configured such that it can be broken off and attached to the outside of the larger assembly or end device. In this manner, the RFID tag can be used to continue tracking the PCB all the way through the end of the manufacturing process. Accordingly, tracking information can be more efficiently correlated and used to improve inventory tracking, failure trend spotting analysis, and to improve service by providing information that can quickly identify potential problems in a failed field unit.

Description:
RELATED APPLICATIONS INFORMATION  
       [0001]     This application claims priority under 35 U.S.C. 119(e) to Provisional Patent Application Ser. No. 60/805,423, entitled “An RFID Smart Cabinet and a Multi-Document Read Write Station,” filed Jun. 21, 2006, which is incorporated herein by reference as if set forth in full. 
     
    
     BACKGROUND  
       [0002]     1. Field of the Invention  
         [0003]     The field of the invention relates generally to Radio Frequency Identification (RFID) systems and more particularly to the design and construction of RFID tags used for tracking the assembly of various devices.  
         [0004]     2. Background of the Invention  
         [0005]     In complex manufacturing processes, such as the manufacturing of consumer electronics, hundreds or even thousands of parts are assembled to make a single device. It is important to track these components as they go through the manufacturing process. Often logs are used to track components using some form of serial number as they go through the manufacturing process; however, as smaller components get assembled into larger components and ultimately into the end device it can be difficult to continue tracking such components. Moreover, current logging systems can be disparate and difficult to correlate information associated with a specific component.  
         [0006]     In certain situations, bar codes or other technology can be used to assist in tracking components as they are assembled in the manufacturing process. Thus, as a component comes to a new station from the manufacturing process it can be scanned, e.g., using a bar code scanner, and information related to the component can be tracked in an electronic database. RFID technology has the added advantage in that line of sight is not required to effectively scan an RFID tag being used to track a component. Even with RFID technology, however, it can be difficult to continue tracking components as they are assembled in the larger assembles because even though line of sight is not required, other components and circuitry can interfere with the ability to effectively read an RFID tag once a component associated with the tag has been assembled into a larger device.  
         [0007]     The inability to efficiently track components up to the device level hinders the ability to efficiently track information that can used to spot trends, such as the failure trends, to assist in servicing failed devices, and in keeping efficient inventory records.  
       SUMMARY  
       [0008]     A breakaway RFID tag is configured such that it comprises part of a Printed Circuit Board Assembly (PCB). Thus, the breakaway RFID tag can be used to track the PCB as it migrates through a manufacturing process. In one embodiment, the RFID tag can be assembled first and then used to track the PCB as it is populated with components and installed into larger assemblies and ultimately into the end device. Once the PCB is installed into a larger assembly or the end device, the breakaway RFID tag is configured such that it can be broken off and attached to the outside of the larger assembly or end device. In this manner, the RFID tag can be used to continue tracking the PCB all the way through the end of the manufacturing process. Accordingly, tracking information can be more efficiently correlated and used to improve inventory tracking, failure trend spotting analysis, and to improve service by providing information that can quickly identify potential problems in a failed field unit.  
         [0009]     These and other features, aspects, and embodiments of the invention are described below in the section entitled “Detailed Description.” 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     Features, aspects, and embodiments of the inventions are described in conjunction with the accompanying drawings, in which:  
         [0011]      FIG. 1  is a diagram illustrating an exemplary RFID system;  
         [0012]      FIG. 2  is a diagram illustrating an example printed circuit board comprising a breakaway RFID tag in accordance with one embodiment of the inventor;  
         [0013]      FIG. 3  is a diagram illustrating an example method for tracking an assembly process using the breakaway RFID tag of  FIG. 2  in accordance with one embodiment of the invention;  
         [0014]      FIG. 4  is a diagram illustrating an example of assembly process for the printed circuit board of  FIG. 2 ; and,  
         [0015]      FIG. 5  is a diagram illustrating a method of troubleshooting an assembly process using information retrieved from the breakaway RFID tag of  FIG. 2 . 
     
    
     DETAILED DESCRIPTION  
       [0016]      FIG. 1  is a diagram illustrating an exemplary RFID system  100 . As can be seen RFID system  100  comprises an RFID interrogator  102 , an antenna or a coil  108 , and a transponder, or RFID tag  112 . RFID interrogator  102  communicates with RFID tag  112  over an RF communication channel  136 . RFID tag  112  can be passive or active. In the active case, RFID tag  112  can comprise its own power source, which can allow it to store more information. In the passive case, RFID tag  112  uses the energy in the signal received over RF channel  136  to power up a small transponder circuit. The transponder circuit is configured to read the instructions transmitted by RFID interrogator over RF channel  136  and respond accordingly. Often, the instructions received from RFID interrogator  102  require the transponder circuit to read a small amount of information stored in a memory circuit on RFID tag  112  and transmit the information back to RFID interrogator  102  over RF channel  136 . The passive RFID tag  112  typically does not generate an RF signal to be transmitted over RF channel  136 . Rather, RFID tag  112  simply reflects the received RF signal, while encoding the data retrieved from memory onto the reflected signal.  
         [0017]     Thus, a passive RFID tag comprises a coil, or some form of antenna, and a transponder circuit. A transponder circuit can also include memory circuits for use as described above. The coil or antenna can comprise traces deposited onto a substrate in the same way that traces are deposited onto a PCB substrate. Accordingly, an RFID tag can be manufactured using a PCB substrate with printed traces forming the antenna or coil as well as pads configured to receive a transponder IC. In the systems and methods described below, the ability to make an RFID tag using a PCB substrate and traces is taken advantage of to track the PCB state assembly process by manufacturing the PCBs with a breakaway RFID tag that can be used to track the PCB as components are populated thereon and as the PCB is assembled into larger component assemblies and/or into the end device.  
         [0018]      FIG. 2  is a diagram illustrating an example Printed Circuit Board (PCB)  200  comprising a breakaway RFID tag  201  connected to main body  205  by a breakaway connection  204  in accordance with one embodiment of the invention. Main body  205  can comprise traces for interconnecting other components that are essential to the functioning of the assembled PCB  200 . Breakaway RFID tag  200  can comprise a printed antenna  202  and an integrated circuit (IC) pad  203 . IC pad  203  can be configured to receive an RFID transponder IC  206 . Thus, IC pad  203  can be of several types, depending on the processes and technology used for a particular implementation. For example, IC pad  206  can comprise a surface mount pad or a dual axial lead pad, just to name a couple.  
         [0019]     Accordingly, breakaway RFID tag  201  can be populated, e.g., with transponder IC  206 , before main body  205  is populated with any associated components. A breakaway RFID tag can then be used to begin tracking information related to the assembly of main body portion  205  until main body portion  205  is to be assembled into a larger component assembly. The breakaway RFID tag can then be broken away from main body portion  205  by breaking breakaway connection  204 . The breakaway connection  204  can then used to continue tracking the component assembly into which main body portion  205  was assembled. Thus, breakaway connection  204  can simply comprise a narrow portion of PCB substrate that can be snapped off when required. Alternatively, breakaway connection  204  can comprise a PCB substrate that is perforated with holes in order to make it easier to snap off and break away RFID tag  101 . In other embodiments, breakaway connection  204  can be configured such that it can be cut, i.e., using a knife, scissors, or the like, or even sawed in order to disconnect breakaway RFID tag  201  from main body portion  205 .  
         [0020]      FIG. 3  is a flowchart illustrating an example method for tracking an assembly process using, e.g., breakaway RFID tag  201  in accordance with one embodiment of the systems and methods described herein. First, in step  301 , a PCB  200  comprising main body portion  205 , breakaway connection  204 , and breakaway RFID tag  201  is fabricated using known fabrication techniques. Again, breakaway RFID tag  201  should at least include a printed coil, or antenna,  202  and an IC pad  203 . IC pad  203  can be of several types, e.g., including a surface mount pad or a dual axial lead pad. Main body portion  205  can contain pads and interconnects for assembling and connecting other components.  
         [0021]     After fabricating PCB  200  with breakaway tag  201 , IC pad  203  can be populated with an RFID transponder IC  206  in step  302 . RFID transponder IC  206  can be populated onto breakaway RFID tag  201  using a number of different methods, including surface mounting or dual axial lead mounting, depending on the type of transponder IC  206  and IC pad  203 . Once RFID transponder  206  has been assembled onto breakaway RFID tag  201 , RFID tag  201  can be scanned to record any associated identification information in step  303 . The recorded identification information can, for example, be used for tracking or troubleshooting as will be described below. In addition to the identification information, other information such as the time, can be recorded as well.  
         [0022]     In certain embodiments, PCB  200  can then be assembled into a larger assembly without any further processing, as illustrated in step  208 . Once PCB  200  is assembled into a larger assembly, breakaway RFID tag  201  can be detached from main body portion  205  and attached to the exterior surface of the assembly, as illustrated in step  309 . As mentioned above, placing breakaway RFID tag  201  on the exterior surface of the assembly allows breakaway RFID tag  201  to continue performing its tracking function once main body portion  205  has been incorporated within the assembly. Thus, breakaway RFID tag  201  can be used to track the assembly into which main body portion  205  has been assembled. Tracking can be performed simply by scanning, in step  310 , breakaway RFID tag  201  and recording its identifying information. In addition to the identifying information for each breakaway RFID tag  201 , it is possible to record other information such as the time of the scan.  
         [0023]     PCB  200  can, however, be subject to further assembly processes before it is incorporated into a larger assembly in step  308 . For example, main body portion  205  can be populated with other components in multiple processing steps, as illustrated in step  304 . After each additional processing step  304 , breakaway RFID tag  201 , which can still be attached to main body portion  205 , can be scanned and recorded in step  305 . The additional processing performed on the PCB  204  may consist of many smaller steps. Thus, several additional processing steps  304  are required, breakaway RFID tag  301  can be scanned and information recorded after each step.  
         [0024]     Breakaway RFID tag  201  can also be used to track and/or record when repairs, or abnormal processing steps, occur in relation to main body portion  205 . Thus, if it is determined, in step  306 , that repairs are needed, then PCB  200  can be routed to a repair station. Breakaway RFID tag can be used to track the occurrence of the repair, e.g., scanning, in step  307 , breakaway RFID tag  201  as PCB  200  enters and/or exits the repair station to record the identifying information of breakaway RFID tag  201  and, optionally, additional information.  
         [0025]     As should be apparent, scanning RFID tag  201  at various steps in the assembly process can enable the creation of a database of information related to the assembly process for a particular PCB  200 . RFID tag  201  will often be a passive RFID tag and therefore comprise a limited amount of information. Accordingly, RFID tag  201  will often be used to store little more than an identifier associated with PCB  200 ; however, by integrating the RFID scanners used to scan information from RFID tags  201  with a larger tracking system, assembly operators can provide detailed information for each PCB  200  and associated with the identifier scanned from the associated RFID tag  201 . For example, if a PCB  200  enters a repair station, then the associated breakaway RFID tag  201  can be scanned and then information related to the repairs can be entered, e.g., through a computer. A scanned identifier and related information can then be stored into a database for later retrieval and use. One such use, would be in servicing a failed unit that has been fielded, i.e., sold to a consumer or end user. This is described in more detail below.  
         [0026]     Similarly, breakaway RFID tag  201  can be used to track and/or record repairs to the assembly after breakaway RFID tag  201  has been attached to the exterior of the assembly in step  309 , as illustrated by step  310 . Thus, if it is determined in step  311  that repairs are needed, then they can be made and then those repairs traced using breakaway RFID tags  201 . This can be done by scanning breakaway RFID tag  201  as the assembly enters and/or exits the repair station to record the identifying information of breakaway RFID tag  201  and, optionally, additional information in step  312 .  
         [0027]      FIG. 4  to the diagram is illustrating an example assembly process for a PCB  200  comprising a breakaway RFID tag  201  in accordance with one embodiment of the systems and methods described herein. Thus, as can be seen, the assembly process comprises three assembly steps, step  1 , step  2 , and step  3 , performed at the PCB level. As PCB  200  enters assembly step  1 , RFID tag  201  can be scanned by an RFID scanner  404 . Similarly, as PCB  200  enters step  2  and step  3 , RFID tag  201  can again be scanned by an RFID scanner  404 . Depending on the embodiment, RFID tag  201  can also be scanned by an RFID scanner  404  as it exits one or more of assembly steps  1 ,  2  and  3 .  
         [0028]     In addition, RFID scanners  404  can be interfaced with computer stations  402 . Computer stations  402  can be used to input information related to the assembly of PCB  200 . Any such information, can be associated with information scanned from the associated RFID tag  201 . Computer stations  402  can then be interfaced with a central server  408  so that the scanned information, and any information input through a computer terminal  402  can be stored in a database  410  interfaced with or included in central server  408 .  
         [0029]     Depending on the embodiment, or on the step in the assembly process, little more than the identifying information, and possibly a time step, can be noted in order to attract the assembly of PCB  200 ; however, if there is a problem in the assembly of PCB  200 , then it is often necessary to record additional information so that details related to the problem can be stored in database  410 . For example, as illustrated in  FIG. 4 , PCB  200  may need to enter a repair station during the assembly process. Thus, RFID tag  201  can be scanned as it enters the repair station and information related to the nature of the repairs can be entered through computer terminal  402  and stored in database  410 .  
         [0030]     Once PCB  200  has passed through assembly steps  1 ,  2 , and  3 , and possibly the repair station, it can be assembled into a larger component assembly in the final assembly step for PCB  200 . At this point, breakaway RFID tag  201  can be broken off, or otherwise detached from PCB  200 , and attached to the outside of the final assembly  406 . RFID tag  201  can then be used to track final assembly  406 . Such tracking can include, for example, tracking information related to any repairs made on final assembly  406  as described above.  
         [0031]     It should be noted, that in certain embodiments of RFID scanner  404 , RFID scanner  404  can include a computer system. Thus, computer terminal  402  may not be needed in order to interface RFID scanner  404  with central server  408 . Alternatively, even if RFID scanner  404  includes a computer system, then it can still be interfaced with a computer terminal  402  if required by a particular implementation.  
         [0032]     Once RFID tag  201  is attached to the outside of assembly  406 , it can remain there and be used even after assembly  406  has been fielded, e.g., sold to a consumer.  FIG. 5  is a flowchart illustrating an example method for using RFID tag  201  in order to troubleshoot failures in fielded units in accordance with one embodiment of the systems and methods described herein. Thus, for example, if a unit in the field fails, a technician can be dispatched in order to service the unit. The technician can begin servicing the unit by scanning breakaway RFID tag  201 , in step  502 , attached to the outside of the unit. In step  504 , the information scanned can then be used to access information related to the assembly of the unit. In other words, information stored in database  410  can be accessed and used to identify potential problems with the fielded unit. Thus, in step  506 , information obtained using the scanned information from RFID tag  201  can be used to troubleshoot potential problems with the fielded unit. In particular, if PCB  200  went through a repair station, information related to the repairs can be accessed and analyzed to determine if it is likely that the repairs were insufficient.  
         [0033]     Moreover, as the technician troubleshoots and services the fielded unit, information related to the servicing can be associated with the information scanned from RFID tag  201  and then stored, e.g., in database  410 . Thus, in step  508 , information can be tracked and stored over the lifetime of assembly  406 . The information tracked and stored can, however, easily be correlated and stored for efficient retrieval and use over the lifetime of assembly  406 .  
         [0034]     The information related to servicing of fielded units can be used, for example, to track failure trends and identify problems in the assembly process. For example, if servicing of a plurality of fielded units reveals that the problem is consistently related to portions of PCB  200  that went through a repair station, then this information could be used to ascertain that the repair processes associated with the repair station are inadequate, or are not being implemented correctly. Similarly, information related to consistent failures in the field can be used to identify problems in the assembly process that are not being detected. This information can then be used to implement processes to identify such problems and to implement repair stations to correct the problems when they are identified.  
         [0035]     While certain embodiments of the inventions have been described above, it will be understood that the embodiments described are by way of example only. Accordingly, the inventions should not be limited based on the described embodiments. Rather, the scope of the inventions described herein should only be limited in light of the claims that follow when taken in conjunction with the above description and accompanying drawings.