Abstract:
Apparatus, system, and method for wireless module enabled component carrier for parts inventory and tracking are described.

Description:
BACKGROUND  
       [0001]     Radio Frequency Identification (RFID) is one of many identification technologies used to identify objects. The heart of an RFID system lies in an information carrying module also known as a tag. The module functions in response to a coded RF signal received from a base station. In passive RFID systems where the module is powered by the RFID reader itself, the tag communicates by reflecting the incident RF carrier back to the reader. Information is transferred as the reflected signal is modulated by the module according to a particular programmed information protocol.  
         [0002]     In harsh manufacturing environments, such as a printed circuit board (PCB) assembly plant, most RFID module implementations generally cannot be used more than once. In these applications, RFID modules are generally embedded within a label, and lack the necessary robustness for reuse. In a PCB assembly plant electronic components are stored in component carriers such as trays and/or reels to be delivered to or stuffed in various PCBs on an assembly line by pick and place-machines. Some conventional trays and reels may use serial numbers and bar codes to identify a particular batch of electronic components contained therein. Once installed in a PCB assembly line system, however, there is no way for a controller to read back actual component serial numbers, quantities, and other metrics associated with the components. Furthermore, conventional RFID module systems used in dynamic assembly lines do not provide a way to store data related to a specific tray or reel and cannot track quantities of components remaining therein except, for example, through remote databases. Thus, there exists the possibility of part stuffing errors—placing the wrong component on a PCB or placing a component in the wrong place on a PCB. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0003]      FIG. 1  illustrates a block diagram of a system  100 .  
         [0004]      FIG. 2  illustrates a block diagram of objects  110 ,  112 .  
         [0005]      FIG. 3  illustrates a block diagram of element  116 .  
         [0006]      FIG. 4  illustrates a diagram of assembly  400 .  
         [0007]      FIG. 5  illustrates a diagram of assembly  500 .  
         [0008]      FIG. 6  illustrates a block diagram of a programming logic  600 . 
     
    
     DETAILED DESCRIPTION  
       [0009]      FIG. 1  illustrates a block diagram of an assembly system  100 . Assembly system  100  may comprise, for example, a communication system having multiple nodes. A node may comprise any physical or logical entity having a unique address in system  100 . The unique address may comprise, for example, a network address such as an Internet Protocol (IP) address, a device address such as a Media Access Control (MAC) address, and so forth. Examples of a node may include, but are not necessarily limited to, a computer, server, workstation, laptop, ultra-laptop, handheld computer, telephone, cellular telephone, personal digital assistant (PDA), router, switch, bridge, hub, gateway, wireless access point (WAP), pick-and-place machine operated by a controller, component trays and reels containing communication devices, and so forth. These nodes may include wireless communication modules such as, for example, RFID modules, comprising information associated with components to be assembled on system  100  as well transceivers for reading and writing information to and from the modules. The embodiments are not limited in this context.  
         [0010]     The nodes of system  100  may be arranged to communicate different types of information, such as media information and control information. Media information may refer to any data representing content meant for a user, such as voice information, video information, audio information, text information, alphanumeric symbols, graphics, images, and so forth. Media information may be associated with any data representing components, trays, and/or reels containing the components. For example, media information may include tray and reel serial numbers, lots of electronic components, component serial number portions of a module, component part numbers, initial quantity of components located in trays or reels, and real-time updated quantities of components remaining in trays or reels. Control information may refer to any data representing commands, instructions or control words meant for an automated system, such as an assembly line, or more specifically, for example, an automated PCB assembly line. For example, control information may be used to route media information through system  100 , or instruct a node to process the media information in a predetermined manner.  
         [0011]     The nodes of system  100  may communicate media and control information in accordance with one or more custom or standard protocols. A protocol may comprise a set of predefined rules or instructions to control how the nodes communicate information between each other. The protocol may be defined by one or more protocol standards as promulgated by a standards organization, such as the Internet Engineering Task Force (IETF), International Telecommunications Union (ITU), the Institute of Electrical and Electronics Engineers (IEEE), and so forth. The protocol may be a proprietary custom protocol. More specifically, the protocol may be a RFID module communication protocol.  
         [0012]     Portions of system  100  may be implemented as a wired communication system, a wireless communication system, or any combination thereof. Although system  100  may be illustrated using a particular communications media by way of example, it may be appreciated that the principles and techniques discussed herein may be implemented using any type of communication media and accompanying technology. The embodiments are not limited in this context.  
         [0013]     When implemented as a wireless system, system  100  may include one or more wireless nodes comprising wireless communication modules, such as, for example, RFID modules, interrogators, transceivers, and the like. These wireless nodes may be arranged to communicate information over one or more types of wireless communication media. An example of a wireless communication media may include portions of a wireless spectrum, such as the radio-frequency (RF) spectrum. The wireless nodes may include components and interfaces suitable for communicating information signals over a designated wireless spectrum, such as one or more antennas, wireless transmitters/receivers (“transceivers”), amplifiers, filters, control logic, and so forth. Examples for the antenna may include an internal antenna, an omni-directional antenna, a monopole antenna, a dipole antenna, a lead-frame antenna, an end-fed antenna, a circularly polarized antenna, a patch antenna, a plane-inverted F antenna, a micro-strip antenna, a diversity antenna, a dual antenna, an antenna array, and so forth. The embodiments are not limited in this context.  
         [0014]     Referring again to  FIG. 1 , system  100  may comprise nodes  102 ,  104 ,  106 , and  108 , for example. Although  FIG. 1  is shown with a limited number of nodes arranged in a certain topology, it may be appreciated that system  100  may include additional or fewer nodes arranged in any type of topology desired for a given implementation. The nodes  102 ,  104 ,  106 , and  108  may communicate via wired communication links  118 , wireless communication links  120  or any combination thereof, for example. The embodiments are not limited in this context.  
         [0015]     In one embodiment, system  100  may comprise node  102 . Node  102  may represent, for example, a pick-and-place machine to pick electronic components (e.g., integrated circuits (ICs) and other electronic parts) from trays  110  and reels  112  and place them on PCBs  122  at node  104 . Node  102  also may comprise a controller to control one or more operations associated with pick-and-place machines, trays, reels, and assembly lines.  
         [0016]     In one embodiment, node  102  may further comprise a communication element. Among other elements and functions, the communication element may include a wireless transceiver  116 , for example, to communicate between node  102  and nodes  104 ,  106 , and  108 . For example, transceiver  116  may be configured to communicate with one or more wireless modules, such as, for example, RFID modules  114  located throughout a PCB manufacturing plant. In one embodiment, transceiver  116  may communicate with RFID modules  114  at nodes  108  and  110 .  
         [0017]     System  100  may comprise node  106 . In one embodiment, node  106  may represent, for example, an element for dispensing components to the assembly line system of node  104 , for example. Node  106  may further comprise one or more objects  110  containing components to be dispensed by the pick-and-place machine. The object  110  may comprise, for example, a reel containing electronic components to be assembled on PCBs  122 . In one embodiment, object  110  may further comprise a wireless communication module, such as, for example, an RFID module  114 , which may be embedded within the material comprising object  110  and may form an integral part thereof.  
         [0018]     System  100  may comprise node  108 . In one embodiment, node  108  may represent, for example, an element for dispensing components to the assembly line system of node  104 , for example. Node  108  may further comprise one or more objects  112  containing components to be dispended by the pick-and-place machine. The object  112  may comprise, for example, a component carrier such as a tray containing electronic components to be assembled on PCBs  122  by the pick-and-place machine. The object  112  may comprise, for example, a tray containing electronic components to be assembled on PCBs  122 . In one embodiment, object  110  may further comprise an RFID module  114 , which may be embedded within the material comprising object  112  and may form an integral part thereof.  
         [0019]     System  100  may comprise node  104 . In one embodiment, node  104  may represent, for example, an assembly line system interfaced with one or more pick-and-place machines associated with node  102 , for example. In one embodiment, the assembly may be configured to assemble PCBs  122 . In one embodiment, the PCB assembly line system may be manual, semi-automated, automated or any combination thereof.  
         [0020]     In general operation, system  100  may comprise a dynamic assembly line to monitor and update component selection and placement. In one embodiment, system  100  may communicate information between node  102  and nodes  104 ,  106 , and  108  and, at any time, simultaneously read and write information from and to the RFID modules  114  located throughout the system  100 . For example, transceiver  116  may read and write information from and to the RFID modules  114  to track the serial number of each object  110 ,  112  and lots of components contained therein. In one embodiment, portions of each RFID module  114  may be write once or pre-programmed for this function. Transceiver  116  also may read component part numbers stored in RFID modules  114  in objects  110 ,  112 , for example. Transceiver  116  also may read a quantity of components contained in an object  110 ,  112  and may update the actual quantity of components remaining in each object  110 ,  112  as they are consumed in the assembly process. The remaining quantity may be stored, for example, in a re-writable portion of RFID module  114  and may be updated in real time by transceiver  116  under control of pick-and-place or machine or dispenser machines.  
         [0021]      FIG. 2  illustrates a block diagram  200  of objects  110 ,  112  comprising a wireless communication module, such as, for example, RFID module  114 . As shown in  FIG. 2 , objects  110  and  112  each may comprise RFID module  114  comprising multiple elements some of which may be implemented using, for example, one or more circuits, components, registers, processors, software subroutines, or any combination thereof. Although  FIG. 2  shows a limited number of elements, it can be appreciated that objects  110 ,  112  may comprise additional or fewer elements as may be desired for a given implementation. The embodiments are not limited in this context.  
         [0022]     In one embodiment, RFID module  114  comprises a semiconductor integrated circuit  202  (IC) that includes radio frequency (RF) circuit  204  connected to antenna  210 , logic  206 , and memory  208 . A specific RFID  114  module may either be ultra high frequency (UHF), Microwave Frequency (μW), or high frequency (HF). Logic  206  may comprise, for example, a processor, controller, state machine, programmable logic array, and the like, and may operate under the control of program instructions. Memory  208  may comprise, for example, program memory, data memory or any combination thereof. Memory  208  also may comprise, for example, random access memory (RAM), read only memory (ROM), programmable read only memory (PROM), erasable programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), combinations thereof, and the like. In one embodiment, memory  208  may be re-writable. RFID module  114  also may comprise antenna  210  connected to RF circuit  202 . Those skilled in the art will appreciate that the IC  202  may or may not include RF circuit  204 . Often, RF circuit  204  may comprise, for example, a collection of discrete components such as, capacitors, transistors, and -diodes that may be located off the IC  202 . Active RFID modules may further comprise a battery. Passive RFID modules have no battery. Rather, they derive their energy from the RF signal used to interrogate the RFID module  114 . For example, RFID module  114  may derive and store voltage from a reactive circuit that is responsive to an RF interrogation signal. Such a circuit may comprise, for example, an inductive coil, rectifying circuitry, a storage capacitor, and related circuitry permitting the RFID module  114  to respond to an interrogation signal while present in the present in the electromagnetic field of the interrogation signal. This results in storage on the capacitor of sufficient voltage to power a desired operation of the RFID module  114 . In one embodiment, RFID module  114  may be a passive type RFID module. Alternatively, RFID module  114  may comprise a battery for a power source.  
         [0023]     In general, RFID module  114  may be manufactured by mounting the antenna  210  element and other individual elements to the IC  202 . This may be done by using either short wire bond connections or soldered connections such as ball grid array (bumps) between the semiconductor chip and other circuit elements: RF circuit  202  (e.g., capacitors, diodes, transistors, etc.), antenna  210 , logic  206 , memory  208 , and so forth. Antenna  210  may comprise loops of wire or may be metal etched or plated and soldered or wire bonded to the IC  202 . In one embodiment, antenna  210  may comprise, for example, a lead-frame antenna. In one embodiment, IC  202  may be supported by a custom lead-frame which serves as its support and antenna. IC  202  may be either wire-bonded to the lead-frame for the antenna or bumped and flipped onto it prior to over molding. The entire RFID module  114  assembly comprising elements  202 ,  204 ,  206 ,  208  may be embedded in and form an integral part of elements  110 ,  112  providing a means of physical enclosure. In one embodiment, RFID module  114 , including IC  202  and antenna  210 , may be injection molded into plastic component carrier such as a device tray or component reel which is molded over passive RFID module  114  including antenna  210 . For example, embedding RFID module  114  with a component carrier by injection molding it along with a supportive lead-frame antenna provides a higher degree of reliability and may provide for advanced parts handling and manufacturing control.  
         [0024]      FIG. 3  illustrates a block diagram  300  of elements comprising transceiver  116 . As shown in  FIG. 3 , transceiver  116  may comprise multiple elements some of which may be implemented using, for example, one or more circuits, components, registers, processors, software subroutines, or any combination thereof. Although  FIG. 3  shows a limited number of elements, it can be appreciated that more or less elements may be used for a given implementation. The embodiments are not limited in this context. In one embodiment, transceiver  116  comprises IC  302  that includes RF circuit  304  connected to antenna  310 , logic  306 , and memory  308 . Logic  306  may comprise, for example, a processor, controller, state machine, programmable logic array, and the like, and may operate under the control of program instructions. Memory  306  may comprise, for example, program memory, data memory or any combination thereof. Memory  306  also may comprise, for example, random access memory (RAM), read only memory (ROM), programmable read only memory (PROM), erasable programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), combinations thereof, and the like. RF circuit  302  also may comprise RF transmitter and receiver portions, each comprising, for example, a collection of discrete components such as, capacitors, transistors, diodes, and integrated circuits.  
         [0025]     When system  100  wishes to obtain information contained in the wireless communication modules, such as, for example, RFID modules  114 , or update information therein, transceiver  116  interrogates the distributed RFID modules  114  by outputting an RF interrogation signal. In accordance with a program stored within a program memory portion of memory  308 , logic  306  causes the RF circuit  403  to periodically output an interrogation signal at antenna  310  to interrogate the one or more RFID modules  114  distributed throughout system  100  ( FIG. 1 ). The interrogation signal may be output, for example, at predetermined intervals of 1 ms, for example. By way of example, antenna  310  permits communication of data between transceiver  116  at node  102  and RFID modules  114  at nodes  106 ,  108  through an electromagnetic fields emitted by transceiver  116  and RFID modules  114 . In response to the interrogation signal, received by RFID modules  114  at antenna  210 , RFID module  114  logic  206 , under control of a program stored within a program memory portion of memory  208 , causes RFID modules  114  to output identification data to transceiver  116  at node  102 . The identification data may include, for example, serial numbers of each object  110 ,  112 , serial numbers for tracking component lots contained in objects  110 ,  112 , serial number portion of the RFID module  114 , part numbers of devices contained in objects  110 ,  112 , quantity of devices, serial numbers or model numbers of pick-and-place or dispenser machines, real-time updates of quantity of devices or components in objects  110 ,  112 , and so forth. Upon receipt of that identification data, transceiver  116  determines whether to take actions to enhance the performance of system  100  or to enhance the dynamic assembly lines and reduce erroneous component selection and placement.  
         [0026]      FIG. 4  illustrates one embodiment of a tape and reel assembly  400  to carry electronic components. Assembly  400  comprises a reel  402  that carries tape during component feeding. The tape carries a plurality of electronic components to feed to a pick-and-place machine. Reel  402  further comprises an arbor hole  404  for mounting reel  402  on pick-and-place machine. Reel  402  further comprises one embodiment of a passive RFID module  406  to identify information associated with the components. In one embodiment passive RFID module  406  comprises integrated circuit  408  (IC) and lead-frame  410 .  
         [0027]     Reel  402  may be an injection molded component reel that is over molded over passive RFID module  406  including its lead-frame. In one embodiment, RFID module  406  structure may be embedded within an injection molded reel  402  so that it may easily be cleaned and recycled, for example. One embodiment of an antenna structure comprises a stamped lead-frame antenna that supports the RFID module semiconductor chip during injection over-molding. The semiconductor chip either may be wirebonded or flipped onto this lead-frame antenna structure. The specific RFID module  406  may either be UHF or HF and, in one embodiment, may be re-writable to cover a large number of applications. As shown, IC  408  is supported by custom lead-frame  410 , which serves as RFID module&#39;s  406  support and antenna. RFID module IC  408  may be either wire-bonded to the lead-frame for the antenna or bumped and flipped onto it prior to over molding. Pick-and-place machines that take reel  402  may be equipped with a single reader, such as transceiver  116  shown in  FIGS. 1 and 3 , capable of simultaneously reading/writing to a plurality of reels  402  equipped with RFID modules  406  in an assembly environment at any time.  
         [0028]      FIG. 5  illustrates one embodiment of a device tray assembly  500  to carry electronic components. Assembly  500  comprises a tray  502  that includes a plurality of cells  504  to hold components during feeding. The tray  502  carries a plurality of electronic components to feed to a pick-and-place machine. Tray  502  further comprises one embodiment of a passive RFID module  506  to identify information associated with the components. In one embodiment passive RFID module  506  comprises integrated circuit  508  (IC) and lead-frame  510 .  
         [0029]     Tray  502  may be an injection molded component tray that is over molded over passive RFID module  506  including its lead-frame. The specific RFID module  506  may either be UHF or HF and, in one embodiment, may be re-writable to cover a large number of applications. As shown, IC  508  is supported by custom lead-frame  510 , which serves as RFID module&#39;s  506  support and antenna. RFID module IC  508  may be either wire-bonded to the lead-frame for the antenna or bumped and flipped onto it prior to over molding. Pick-and-place machines that take tray  502  may be equipped with a single reader, such as transceiver  116  shown in  FIGS. 1 and 3 , capable of simultaneously reading/writing to a plurality of trays  502  equipped with RFID modules  506  in an assembly environment at any time. Tray  502  may include any device tray, such as, for example, quad flat package (QFP), ball grid array (BGA) package, quad flat no-lead/micro lead frame (QFN/MLF) package, thin shrink small outline package (TSSOP), and other package types for use in a given pick-and-place machine.  
         [0030]     Operations for the above system and subsystem may be further described with reference to the following figures and accompanying examples. Some of the figures may include programming logic. Although such figures presented herein may include a particular programming logic, it can be appreciated that the programming logic merely provides an example of how the general functionality described herein can be implemented. Further, the given programming logic does not necessarily have to be executed in the order presented unless otherwise indicated. In addition, the given programming logic may be implemented by a hardware element, a software element executed by a processor, or any combination thereof. The embodiments are not limited in this context.  
         [0031]      FIG. 6  illustrates a programming logic  600 . Programming logic  600  may be representative of the operations executed by one or more systems described herein, such as system  100 . As shown in programming logic  600 , at block  610  the system transmits an interrogation signal with a transceiver. In one embodiment, transmitting an interrogation signal comprises transmitting a plurality of signals. At block  620 , the one or more RFID modules distributed throughout the system receive the interrogation signal. At block  630 , the one or more RFID modules transmit information to the transceiver in response to the interrogation signal. In one embodiment, the information may be transmitted by the RFID modules simultaneously. Further, in one embodiment, the information may comprise, for example, any of, some, or all of the following: a component carrier serial number; a component serial number; a component part number; a number of components in the component carrier; and a number of components remaining in said component carrier.  
         [0032]     Numerous specific details have been set forth herein to provide a thorough understanding of the embodiments. It will be understood by those skilled in the art, however, that the embodiments may be practiced without these specific details. In other instances, well-known operations, components and circuits have not been described in detail so as not to obscure the embodiments. It can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.  
         [0033]     It is also worthy to note that any reference to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.  
         [0034]     Some embodiments may be implemented using an architecture that may vary in accordance with any number of factors, such as desired computational rate, power levels, heat tolerances, processing cycle budget, input data rates, output data rates, memory resources, data bus speeds and other performance constraints. For example, an embodiment may be implemented using software executed by a general-purpose or special-purpose processor. In another example, an embodiment may be implemented as dedicated hardware, such as a circuit, an application specific integrated circuit (ASIC), Programmable Logic Device (PLD) or digital signal processor (DSP), and so forth. In yet another example, an embodiment may be implemented by any combination of programmed general-purpose computer components and custom hardware components. The embodiments are not limited in this context.  
         [0035]     Some embodiments may be described using the expression “coupled” and “connected” along with their derivatives. It should be understood that these terms are not intended as synonyms for each other. For example, some embodiments may be described using the term “connected” to indicate that two or more elements are in direct physical or electrical contact with each other. In another example, some embodiments may be described using the term “coupled” to indicate that two or more elements are in direct physical or electrical contact. The term “coupled,” however, may also mean that two or more elements are not in direct contact with each other, but yet still co-operate or interact with each other. The embodiments are not limited in this context.  
         [0036]     Some embodiments may be implemented, for example, using a machine-readable medium or article which may store an instruction or a set of instructions that, if executed by a machine, may cause the machine to perform a method and/or operations in accordance with the embodiments. Such a machine may include, for example, any suitable processing platform, computing platform, computing device, processing device, computing system, processing system, computer, processor, or the like, and may be implemented using any suitable combination of hardware and/or software. The machine-readable medium or article may include, for example, any suitable type of memory unit, memory device, memory article, memory medium, storage device, storage article, storage medium and/or storage unit, for example, memory, removable or non-removable media, erasable or non-erasable media, writeable or re-writeable media, digital or analog media, hard disk, floppy disk, Compact Disk Read Only Memory (CD-ROM), Compact Disk Recordable (CD-R), Compact Disk Rewriteable (CD-RW), optical disk, magnetic media, various types of Digital Versatile Disk (DVD), a tape, a cassette, or the like. The instructions may include any suitable type of code, such as source code, compiled code, interpreted code, executable code, static code, dynamic code, and the like. The instructions may be implemented using any suitable high-level, low-level, object-oriented, visual, compiled and/or interpreted programming language, such as C, C++, Java, BASIC, Perl, Matlab, Pascal, Visual BASIC, assembly language, machine code, and so forth. The embodiments are not limited in this context.  
         [0037]     Unless specifically stated otherwise, it may be appreciated that terms such as “processing,” “computing,” “calculating,” “determining,” or the like, refer to the action and/or processes of a computer or computing system, or similar electronic computing device, that manipulates and/or transforms data represented as physical quantities (e.g., electronic) within the computing system&#39;s registers and/or memories into other data similarly represented as physical quantities within the computing system&#39;s memories, registers or other such information storage, transmission or display devices. The embodiments are not limited in this context.  
         [0038]     While certain features of the embodiments have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the embodiments.