Class Schedule - an overview

• 01: Welcome and Overview of the class and of the 5DX system.
• 02: Theory of Operation, Hardware and Safety
− How the 5DX works
− Anatomy of the 5DX hardware.
− Safety
• 03: Test Program Development Overview and start the development.
− The first panel to be programmed will focus on teaching the overall
development process and three specific test algorithms.
− The second panel to be programmed will repeat the process and teach the
algorithms in greater detail.
• 04: CAD Translation
− Translate the CAD description of the Zorro Board into a "project" that
the 5DX software will use during the development of the test.

05: Finish the Panel Description.
- The first step is to translate the CAD data, but this does not provide all
the information needed by the 5DX to test the panel.
- Discover what details are missing and add those details.
- The first compile may generate errors and warnings.
• Learn to read the compilation (translation) report.
• Learn how to make unimportant warnings disappear.
- Use the Program Advisor to check your descriptions. While a description
may be syntactically correct (passes the compiler), it may not be
logically correct. Use the Compiler and the Advisor before continuing.
- Troubleshoot your work so errors are found and corrected quickly.
• 06: Transfer to the 5DX.
- When the description is complete, archive the development into the CAD
Database. This database is used at the 5DX to load the development and
begin testing.
Day 3
• 07: First Time at the 5DX
- Use the CAD Database to complete the transfer of the test development
from the Test Development Workstation (TDW) to the 5DX controller.
− Load the panel into the 5DX.
− Use the Alignment tools to locate the exact position of the panel. The
first time this is done, it is a manual process.
− Use the Surface Map tools to create a contour map of the panel. This tells
the 5DX about board warpage. Given those details, the system can
maintain properly focused images even where the panel is warped.
− View Verifier - Verify that the images and the data translated from the
CAD agrees. Also, verify the quality of the images. Out of focus images
are difficult to use.
− Collect images - Update the development work in the TDW's CAD
Database and capture images of the panel, copying those images to the
TDW.
• 08: Overview of the Tuning Process.
− Become familiar with the tools used when turning on tests.

Learning Objectives for Module 01

When you have completed this module of training, you will be able to:
• Correctly describe the purpose and expectations of the 5DX Test Developer’s
training.
• Correctly describe the steps in the 5DX test development process.
• You will be able to develop a test for a printed circuit board.
- You will probably need some additional help, from a co-worker or from
Agilent. To minimize this:
• The class uses on-line documentation and help tools.
• During the development of the first panel, the instructor will be
present and coaching during all labs.
• During the second panel's development, the instructor will act as
an Agilent Systems Engineer / Applications Engineer. You can
call on the instructor for help in much the same way as you
would your local Agilent representative. (After attempting to
solve the problem on your own using the class workbook, on-line
help and some experimentation. If you cannot find the
information needed within three minutes, ask the instructor.)

Our goal in using this scenario is to:
− a) Teach every student how to solve problems without
assistance.
When asked for help, the instructor's first effort will be to help
find the answer in the on-line help / documentation. Thus
demonstrating the self-supporting tools available on the system.
− b) The three minute rule is used so everyone will use the tools,
but not so long that it creates frustration.
Methods used to teach the 5DX
• Lectures will describe the concepts of test.
- Students are expected to participate with questions and feedback.
- Students will work in pairs. It is assumed that students will learn as
much from their partner as from the instructor.
• Labs will reinforce those concepts with practical experience.
The labs early in the class have step-by-step instructions. Later in the class, the labs will
be less step-by-step. As you are doing the labs, stop and ask yourself and your partner,
“What are we doing?”. “What did we just do?”, “Why did we do it this way?”…
• Labs
- Instructor Lead Labs: Initially, the instructor will lead the class through a
new process. The instructor will perform the process, one step at a time,
while the class does the same. In all cases, the class manual includes the
same instructions, so no one has to take notes while performing the
exercise.
- Independent Labs: Usually, these same tasks are performed again during
an independent lab following the instructor-lead lab using different files
or panels.
• Review the Student Workbooks the night before the lecture. This will help
you learn more during the class.

Electromagnetic-Spectrum

Radiation X - (consisting of the X - ray) is a form of electromagnetic radiation, X - rays have a wavelength in the range 0.01 to 10 nm, corresponding to frequencies in the range petahertz 30-30 exahertz (3 ? Hz. 1016-3 ? 1,019 Hz) and energies in the range 120 to 120 eV keV, they are shorter than the wavelength of UV light and longer than gamma rays in many languages, X rays are called radiation R6ntgen after Wilhelm Conrad R6ntgen is usually credited. is the discovery of X rays, and those with a meaningful name that does not know the spelling. radiation.Correct of X - ray (s) in the English language including variables, X - ray (s) and X - ray (s). Xray is a phonetic pronunciation for the letter X.

X - rays of about 0.12 - 12 keV (wavelength, nm 10-.10) are classified as "soft" X - rays, and from approximately 12-120 keV (0:10 to 0:01 nm wavelength) as the "hard" X - rays. Because of its ability to penetrate them.

The hard X - rays can penetrate solid objects and the use of the most common of them is to take a picture of the inside of the object in the x-ray diagnosis and crystallography. As a result, the X - ray is metonymically. To refer to the radiation produced by this board ? In addition to using their own methods, by contrast, soft X - rays will not penetrate at all attenuation length of 600 EV (~ 2 nm). X - rays in less than 1 micrometer.

The difference between X-rays and gamma rays that have changed in the last decade. The old electromagnetic radiation emitted by the fluorescent X - ray wavelength longer than the radiation emitted by the nucleus of radioactive material (gamma rays), the literature is the difference between the radiation X - and gamma based on a wavelength with shorter wavelength radiation, such as arbitrary as 10-11 meters under the gamma rays. However, as shorter wavelength continuous spectrum "X - ray" sources such as linear accelerators and wavelength "gamma ray" emitters. Was discovered in the wavelengths that overlap the most. Both types of radiation is dominant now, often by their origins: X - rays are emitted by electrons outside the nucleus, while gamma rays emitted from the nucleus. that

Types of BGAs - Ceramic 1

The Ceramic Ball Grid Array usually has Non-Collapsible balls.
• The BGA balls are made of a higher temperature material. Either a greater
Lead content or a greater Tin content means the balls will not melt under
normal reflow conditions.
• The BGA balls retain their nearly spherical shape after reflow.
• The x-ray diameter of the ball can have certain assumptions made:
− The largest diameter of the ball is at the ball's radius above the panel
(TOP + radius) as specified in a data sheet.
− The x-ray image of the solder joint at the panel (TOP) is about 1/2 the
diameter of the ball.
− The x-ray image of the solder joint at the device (TOP + diameter) is
about 1/2 the diameter of the ball also.
• Set the slice heights
− The first slice is at TOP + radius. This is at the maximum diameter.
− The device slice is set at TOP + (1.5 x radius). This places it slightly
below the device, but close enough to see any faults with the joint at the
device.
− An optional third slice is at TOP. This is used by the Short Test
algorithm only.

How 3D x-ray inspection machine work?

Testing a Panel and/or a Board

Testing a Panel and/or a Board

• It is not unusual for you to receive a board to develop a test, but be told to
expect a multi-up panel when released to production. If this happens, you
will develop the test for a single board and return later to describe the panel
of boards.
− If a carrier is needed for the individual board, but not for the panel, keep
the carrier, you may need it when testing individual boards that have
been broken out of the panel during the repair process.
• Bill or material, CAD data, etc. has been gathered. These will be provided as
needed. (See lab at end of module.)
• For the Zorro Panel, the CAD describes:
− A single board.
− The integrated circuits on the bottom of the board. The finest pitch parts
should be face-up when loaded. Therefore, the panel must be turned over
when placed in the carrier.
− To optimize movement inside the 5DX, the board should be oriented
vertically (the longer axis on the Y-axis).
− The software references the placement by the distance from the carrier's
origin (0,0) to the board's origin (0,0).
During the lab, the exact dimensions will be provided.

CAMCAD is divided into separate functions.
• Setup the Translator to recognize a specific CAD format
- This prepares the translator to accept CAD input from a specific CAD
system.
- This is similar to expecting the input language to be German, French,
Japanese or Korean…
• Import the CAD data.
This Pre-Processes the CAD Data.
- This allows one translator to accept very different CAD inputs. Each
CAD system has its own formats and its own Pre-Processor. Each
converts the CAD into a common format that a single translator can
interpret.
• Manually process the CAD data as needed.
- Manually manipulate the panel description.
- If you want to include Fiducials, you can do so manually.
If you want to exclude Fiducials, you can do so manually…

CAD translation

cad translation

CAD translation
The first step in the development process is to translate the CAD data describing the
printed circuit board so the 5DX can recognize all aspects of the panel.
• Files Needed
The CAD Data file or files.
- Some CAD systems use a single file to describe the panel.
- Some systems use multiple files to describe the panel.
• Tools Used
- CAMCAD generates the information needed by the 5DX.
- Other translators are available. If you already have one of those
translators, you do not have to use CAMCAD.
(Advertisement: Try it, you will be happier with CAMCAD.)
Subsequent Steps - Later Modules
• Finish the panel description
- Having translated the CAD you must complete the panel description.
(Not everything needed to test the panel is available in the CAD.)

• Setup Test Definitions
- Define which joints you want to test and how you want to test them.
• Transfer the development to the 5DX.
• 5DX Test Setup
- Aligning the panel within the 5DX
- Surface Mapping the panel to accommodate warpage
• Verify the Setup and collect images
The processes include:
- The View Verifier process checks that the data and the panel match and
that good focus has been achieved.
- Image Collection. Save test images on the TDW.
• Tune all test Algorithms
- Examine every device-type on the panel and verify that it is being tested
correctly.
- Learn reference/nominal levels for every subtype of device and enter
those references through the interface.
• Release to Production
- Check for differences between the prototype board used in development
and the production boards.
• Engineering Changes
- Adjust the test for changes to the design of the panel.

Why Use X-ray Today

Early Defect Containment
Medium to high complexity products
High reliability/quality requirements by end users
Products with coverage gaps unfilled by other test technologies: Lack of access
Products that require functional test to verify product functionality but lack functional diagnostics
Can reduce manufacturing cost if properly implemented
Partner with other test technologies
No single technique provides complete coverage
ICT/Functional will not be replaced

Where does manufacturing test fit




Multiple manufacturing test strategies, driven by:
Complexity of product
Complexity of repair
End user quality/reliability
Cost of the product
Acceptable manufacturing risk
Volume of product to be built
Deliver the product at the lowest possible cost with acceptable level of quality.
Test is there primarily to ensure end user quality by:
Defect Prevention
Defect Containment

 Are X-Rays Harmful?

Are x-ray hamful ?

X-rays are one of the most used apparatus in hospitals, clinics, and other medical facilities worldwide. It is used to visibly see a bone fracture, a swallowed object, if there's liquid in your lungs, and any other parts of your body without having the doctors open your body up right away. It is an indispensable apparatus which saves doctors time and effort and saves you some money from major surgical operation costs. But, we all know, as a rule of life that everything comes with its pros and cons. So with all of these benefits we get from using X-rays in helping diagnose patients, is exposure to X-ray machines bring disadvantages, too?

Are X-Rays Harmful?

X-ray machines release electromagnetic energy that lets you see your bones, and organs without surgery. This light energy released in the machine is known to be high in radiation. The X-ray is a form of an ionizing radiation which causes chemical reactions to cells when these cells are exposed to the energy emitted by the X-ray machine. You see, when the X-ray hits an atom, the electron of an atom changed into a charged ion that can cause the harmful chemical reactions.
For one, an electrically charged ion can break DNA chains in the body. This can either kill a lot of the living cells inside your body or can cause a mutation. If the number of cells that dies inside you is more than what your body can handle, you may develop diseases and other conditions. On the other hand, if these cells mutate, these can form cancerous tumors that may later on spread on the other parts of the body.
Furthermore, if the cells that mutate are include sperm or egg cells; you may have children with birth defects later on in life. Lastly, X-rays can also have an effect on your bone marrow damaging the cells found on it therefore affecting your hair follicles and skin which causes rashes, hair loss, and other harmful effects.
Because of the risks X-rays can cause due to prolonged or repeated exposures, doctors, dentists and other health care professionals use X-ray machines with a lot of caution and concern. Patients and other people who are being exposed with X-ray machines are asked to wear protective gears just to be safe. X-rays should not be taken unless they are deemed to be necessary or as advice by a doctor as each exposure is harmful to the body.

Article Source: http://EzineArticles.com/6665075

Benefits of X-Rays

X-rays are one of those things that people tend to be wary of. The radiation involved in taking one is a concern. Dentists understand this, and strive to minimize a patient's exposure to the radiation, but they continue to take x-rays because risks of radiation exposure are outweighed by the benefit of what is learned.
X-rays are the best way for a dentist to check a patient's dental health. A dentist can locate cavities in a tooth, show dental abscesses, impacted or extra teeth and even cysts and tumors. Fillings, crowns, bridges and root canals are all facilitated by the use of x-rays. Bone-loss, hidden tartar build-up, and foreign bodies that may be creating dental issues can also be detected by the use of x-rays. Anywhere between two and eighteen may be needed, depending on each patient's situation. Eighteen are needed for a full check-up. Follow ups to check a specific issue require either two or four x-rays. These are referred to as "bite wings." And yet, for all of their benefits patients are still concerned about the radiation levels incurred during an x-ray session.
Dentists, too, are concerned about a patient's exposure to radiation, and so use a high-speed film, and lay a heavy lead vest over the patient before the images are shot. Pregnant women are not given standard x-rays due to the danger to the unborn child, yet dentals are deemed safe due to the relatively low dose of radiation that is received. Dental test send out 58,000 times less radiation than an upper GI, 8,000 times less than a chest and forty times less than the daily radiation that we all experience sitting in front of our televisions or computers, or even just walking around. These figures should go a long way in relieving people of their concerns regarding dental x-rays.
New dental technology now allows for digital x-rays to be taken. The benefits of digital are noteworthy. To start, digital x-rays deliver 80% less radiation than their traditional cousins. That's an 80% reduction to the already low doses of radiation dental x-rays deliver. In addition to lower radiation levels, digitals are almost instantaneous, and the dentist has the advantage of color contrast, since the digital is more like a photo than the traditional black and white. Digital x-rays also eliminate the need for processing chemicals and the cost of film the downside is that the digital technology is more expensive, and the quality of the image is not necessarily any better than a traditional, so not all dentists feel digital x-rays are right for their practice.

Article Source: http://EzineArticles.com/5225200

 

How does the rotating beam work?

How rotating beam work

• For devices on the focal plane:
− A device on the focal plane will be stationary.
− The beam will pass through the device at every angle as it rotates,
creating a three-dimensional, composite image of the device.
− Because the image is a composite of a rotated X-ray beam, the image is
always going to appear slightly fuzzy.
− The advantage, a single composite image represents all aspects of a
solder joint. Therefore, one battery of tests can judge the joints integrity.
− One rotation of the x-ray beam is required to create an image.
(In certain circumstances, up to four rotations of the beam can be used to
create a single image.)
• For devices off the focal plane:
− As the beam rotates, it intersects a device that is off the focal plane at
different points.
− These different points form a circle, the diameter defined by the distance
from the focal plane.
− The image is collected from one rotation of the beam. During that
rotation, the device is "smeared" in the corresponding circle and becomes
simply a shadow.
The 5DX allows you to move the panel on the Z Axis to examine devices on the top of
the panel, the bottom of the panel or internal to the panel.
• The deflection angle of the x-ray beam from 28 to 35 degrees.

Basic 3DX Concept

Basic 3DX Concept
 A Stationary Beam is a “Transmission X-ray”.

Basic 3DX x-ray Concept

X-Ray Concepts
There are two basic ways to image an X-Ray.

• Transmission X-Ray
• Laminography
 

transmission x-ray

Transmission X-Ray:
The X-ray beam that most people are familiar with is the kind used by a doctor or dentist.
These are "transmission" X-rays and regardless of the layering of the objects being xrayed
produce an image of all features.
In the example shown:
• The printed circuit board is positioned between the X-ray source and the
Detector (film).
• There are devices on the top of the panel and
• There are devices on the bottom of the panel.
• The X-rays pass through the devices and the printed circuit board.
• Solder, being a heavy metal, absorbs most of the x-ray energy hitting it.
• The fiberglass of the panel attenuate very little energy.
• The energy that makes it through the panel is collected by the detector.
• This produces an image showing top and bottom devices together, but at
slightly different magnifications.

 basic 3d x-ray laminography

Basic 3DX Concept
A rotating beam is a “Laminography X-ray”.
Laminography X-ray Beam
The Agilent 5DX uses X-ray Laminography.
The X-ray beam is rotating. Deflection coils in the tube cause the photon stream
to pass through the panel at a rotated angle.
Above, four locations are shown, during test, the image is being collected during
the entire 360degree sweep, but examine these four locations:
• The X-rays leave the X-ray tube at position 1
- The beam passes through the device on top of the panel.
- The beam passes through the panel
- The beam passes through devices on the bottom of the panel.
- The image is collected by a detector at its position 1.
• This is repeated at positions 2, 3 and 4.
What is going to be visible?
• All devices on the plane of focus.
• None of the devices above or below the plane of focus.

basic 3d x-ray for PCBA

3d x-ray Theory of Operation

x-ray machine

Learning Objectives
When you have completed this module of training, you will be able to:
• Correctly explain the basic concepts of the 5DX X-Ray Inspection System
including the Theory of Operation.
• Correctly describe the steps in the 5DX application development process.
• Correctly describe the Laminography process and describe the anatomy of
the 5DX system.
• Correctly explain how and why a panel can be tested with x-ray.
• Correctly list and explain the safety procedures of the 5DX system.

laminography x-ray

The Inspection Process
An Overview
The Inspection Process - an Overview
• An X-ray beam passes through a printed circuit board.
- As the beam emerges from the X-ray tube, it is deflected. A series of
deflected x-rays form the circular pattern described earlier.
• Dense metals absorb more of the X-ray's energy than less dense materials.
- A large quantity of solder will appear dark gray, almost black.
- A segment of printed circuit board, without traces or ground plane will
appear light gray, almost white.
- Traces can be seen as slightly darker gray lines.
- Some device packages produce a slightly darker gray area too.
• The X-ray beam reaches the Rotary Scintillator. The Scintillator converts the
X-ray energy into a gray scale image of a solder joint.
- The "Scintillator" has a cesium iodide surface that emits light when
struck by X-rays. (Similar to the phosphors in a picture tube.)
- The X-ray beam is synchronized at 180 degrees following the Rotary
Scintillator. Thus, the beam is rotated through the device being tested.
- During test, the x-ray beam is on continuously. The image is being
collected continuously. Thus, the image is actually a composite, 360
degree view of the solder joint. This is Laminography.

Real time 3D x-ray inspection