Q U I C K P R O G R A M M I N G

G U I D E 2 2 X V 2 . 3

A U T O M A T I C O P T I C A L I N S P E C T I O N
S Y S T E M S

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Contents

Contents 2

PROGRAMMING THE AOI MACHINE 3

1 How to find defects (Measuring) 3

2 Where to check for defects (Coordinating) 3

PROGRAMMING PROTOCOL 4
Programming overview: 4

Preparation: 5

Step A: Modifying the MainStampLibrary (or the company Master Library) 5

Step A: Modifying the MainStampLibrary (or the company Master Library) 6

Step B: Generating PartNumbers (or PartNames) 6

Step C: Identifier (ID) library; Prototype Mode 7

Step D: Combine B+C into one Pack for future use 8

Completing the program 8

PROGRAMMING DETAILS 9
Defining Inspection Depth 9

Frames 10

Stamps 10

Packs 11

Groups(not often used) 12

Differences Groups and Packs 13

Component Identifiers 14

Cells 14

Centroid Data Import 15

Fiducial Markers 16

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P R O G R A M M I N G T H E A O I M A C H I N E
To Program an AOI machine always incorporates two aspects:

1 How to find defects (Measuring)

To measure an object for deciding Good or NotGood (G/NG).

→ Use Quick Filter Guide document

2 Where to check for defects (Coordinating)

To program XY locations for all objects to test

→ Use Quick Programming Guide (this document)

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P R O G R A M M I N G P R O T O C O L
Inspection programs are created by linking Libraries and Centroid (CAD) data.
From start, libraries have to be generated, for optimal efficiency and re-use in the future.

To generate libraries in the most efficient way, a programming protocol has to be executed. Starting point is the
MainStampLibrary from the 22X machine.
The drawing illustrates the creation of the libraries at different levels in the programming process.

Principles to create a good inspection program with lowest efforts:

- Majority of programming time is spent in setting up and debugging the library.
- To save time later, the library should contain as few as possible components in the beginning. Only after
these are set up properly, duplication is started.
- A typical program contains a few different packages (e.g. 0805R, SOT23 etc), Much more different
components (e.g. 20 different resistors 0805 etc), and again much more total components (e.g. R1, R2,
….R200)

Programming overview:
1. Convert the Marantz 22X library into the customers OwnLibrary. This is done on package base to keep the amount
of stamps low.
2. Debug the customers OwnLibrary and save it.
3. Convert the customers (package) OwnLibrary into a part number library.
4. Identifiers and Packages are treated separately. Later they can be merged together.
5. Add identifiers to the part number library to complete it.
6. Create manual frames that are not in the CAD file

Customer/PCB Database (example numbers)

1000cps 1000cps 1000cps 1000cps
22x = 10 = 100 = 100 placed on PCB
Database different different different
packages PartNrs PartNrs
(based on 10 (based on 100
MainStampLibrary
packages) unique
packages)

CAD
PCB
Name2Name
import 3 C
22X Text Copy CAD Name (Copy=On) Identifiers
into Packs
Merge ID

by PartNr
Library CAD XY positions
import 2 of
Identifier
CAD components
+
22X
import 1
Customer
Package Package
by PartNr
N2N D
Use 22X Name (Copy=Off) C-On by PartNr
Package Package
Library
Library Llibrary B A
Llibrary

Name2Name

Name2Name
Cad Import via Name2Name

Cad Import (+ Copy button ON) Cad Import (Copy button OFF)

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The drawing defines 4 steps to set-up an inspection program.

A: Library by Package, without Text. Most fast method. Sets base for steps B and D.

B: Full Part Library, without Part Identifiers (no text inspection for example).

C: Identifier or Presence inspection; No solder inspection.

Also called Prototype Mode; for 1st off inspection.

D: Full Part Library, including Part Identifiers. Best method for future use of library, most time consuming.

Preparation:
1. Switch off Auto-Re-inspect (saves time during debugging)
2. Switch off Speed Priority (to enable bus stop function)
3. Switch off Move via Closest Cell, do not switch this off if you are about linking the CAD file in the “name-name”
window (before teaching).
4. Switch off G/NG classification mode in Viewing Settings Menu (saves time during debugging)

It is good to press Origin and move the camera to the 1st reference point (usually a fiducial point), before opening the
CAD file.

Normal settings during inspection: Settings during Programming:

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Step A: Modifying the MainStampLibrary (or the company Master Library)

1. Load MainStampLibrary or another Master Library
2. Import the CAD file (1st Import)
3. In Name2Name dialog: press name-name if available, link as many as possible components to the library, press
OK when finished.
4. Press START to Start “Teaching”
(Make sure that the Copy button is off in the Stamplist at the first stop of the machine, to avoid that the machine
duplicates stamps with new names) .
5. Link the remaining components during the teaching to the library. Try always to use a library item, if the
component is not in the library, use a pack from the “odd” directory. If totally not possible to use a library item,
draw a frame (try to avoid drawing frames as much as possible as this takes some time later to convert to a pack)
6. Stop the teaching mode when all the components are done. If you are not sure whether the teaching is finished,
wait until the system shows a red NG in the end.
7. Check the rotation of all components and correct if needed
8. Optimise the cells to reduce movement time
9. Switch to the “debugging stamplist” and sort the list by TTL. Start from the top and work your way down by
selecting the components and actualising them one by one:
• Store pictures
• Adjust frame sizes
• Adjust filters
10. After finished all, debug the program and make sure you have no false calls.
11. Save the program with “_A” addition to its name.

Now the inspection program is ready for inspection (based on component package bodies and solder, without
identifiers like text, and polarity).
A minimum amount of library elements results in very fast debugging.
The library is now modified to the specific PCB and this can be used later for the steps B/C/D

Step B: Generating PartNumbers (or PartNames)

1. Start with New File and load the library created by step A. Alternatively you can delete all the cells from the cell
window while the program of step A is still active.
2. Import the CAD file again (2nd import)
3. Press Name2Name button. (Do not link any other stamps! because the system has to generate duplicates of
existing stamps with new names)
4. Press START to Start Teaching
5. Activate the Copy button at 1st stop
6. At 1st stop pick the right stamp from the library (which is created by step A), change the rotation if needed then
press “Enter”
7. Continue until you have done this for all components. Now the machine has made copies of the items in the library
of step A with names from the CAD file.
8. Check the rotation of all components and correct if needed.
9. Optimise cells in the cell window.
10. Run the program. Debugging should minimal.
11. Save the program with “_B” addition to its name.

Now the inspection program is the same as in step A, but the library is much larger and PartNumber based.
It allows the programmer to make specific changes to each component with a different part number.

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Step C: Identifier (ID) library; Prototype Mode

1. While the program from step B is still on and running you can start this step without closing the program.
2. Create a Dummy stamp called e.g. “ Obsolete” (2 spaces in the front will put this stamp always on top of the
Stamplist)
3. Import CAD file again (3rd import).
4. Do NOT Press Name2Name button although all names are existing!
5. Activate Bus Stop in case you want to adjust immediately. Otherwise let is off (recommended for beginners)
6. Press START to Start Teaching
7. At each Stop decide: Identifier Yes/No.
If Yes:
• Activate the Copy button to create the Stamp Name. It will get a “+” extension automatically if the name is
existing already.
• Assign a Text Stamp, Resistor Value check or draw an identifier frame. Create the best photo by closely
surrounding frame around the object to be identified.
If No:
• De-activate the Copy button
• Assign the “ Obsolete” Stamp for easy bulk removal at a later stage.

8. Additionally:
• Fix stored pictures
• Adjust frame sizes
• Adjust filters
• Adjust the search area so that the object ID is in reach from the centre.
9. Now the machine has generated a new “ID-library” with the names from the CAD file
10. Delete “ Obsolete” stamp (including all objects)
11. Optimise cells in the cell window; this is not a “must”.
12. Hide all packs from step B by “Show/Hide objects in Window menu”
13. Debug the Identifier library
14. Save the program with “_C” addition to its name.
st
Now the inspection program performs ID inspection, suitable for 1 -Off inspection.
If loaded together with B, full inspection is performed:
• ID inspection by loose frames (e.g. Pn 1111222+)
• Other item,s by Packs (e.g. Pn 1111222)

For future use it is better to combine the ID frames in the packs of step B.
This process is done by step D.

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Step D: Combine B+C into one Pack for future use

1. Open the debugging stamplist while the program from step B + C is open
2. Sort by Name (this groups e.g. Pn’s “11112222” and “11112222+” together)
3. In the stamplist select both the Pack + ID frame together and press “S” button to hide other stamps.
4. Go to a cell and make sure both Pack + ID are in the same cell.
5. Select them both and Pack them together.
6. Continue until all ID frames are in the Packs.
7. Now all loose ID frames can be deleted.
(To perform this, hide all packs by using Show/Hide objects from “Window” menu, then all cells with ID frames can
be selected and deleted via the Cell menu)
8. Save the program with “D” addition to its name.

Completing the program

To finish a complete inspection program, after finishing steps A-D, perform the following steps:
1. Add manual inspection frames like LeadGaps, odd components, short tests etc.
2. Add fiducial markers before inserting other PCB’s.
3. Perform manual cell optimisation if speed is important.
4. Add CellAidStamps if needed.
5. Multiduplicate if needed (For debugging purposes it is usually needed to perform multi-duplication for debugging
programs A-D too).

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P R O G R A M M I N G D E T A I L S

Defining Inspection Depth

1. What to inspect?

a) Body positioning (Presence, Offset, Rotation)

Body Positioning Frames
Frames NOT built for detecting text

b) Shorts (Leadgap frames)

c) Soldering (Volume + Contact Detection)

Volume detection
Meniscus Yes/No
Meniscus shape

Contact detection (lifted pins, tombstoning etc)

Same as Volume detection but Lead detection also

In order to detect solder quality, define suitable Fillet Frames (multiple or single frames per lead)

d) Component identification (text)

Use normal body checking frame
Use additional frame specially for text checking
(can sometimes replace Body frame)

e) Polarity
Use normal body checking frame
Use additional frame for polarity checking
(can sometimes replace Body frame)

f) Solder Paste (for Paste Inspection)

Use special frames & algorithm for Solder Paste

g) Lost Components detection (Special Cell Function)

This determines the quality of inspection. The quality of inspection can be influenced by:

2. The accuracy of the measurements

→ Use the Quick Filter Guide document
A higher inspection depth means a better way of filtering

3. The number of inspected points

→ Described in this document
A higher inspection depth, means more inspection points, means more programming work.

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Frames
A frame is a subset of pixels from the cell (Field Of View) of the camera used, containing the pixels to inspect.
These pixels should match the reference after calculation its values by formula.

These calculations defined by the “Filter” and determine the tolerance (quality) of inspection.

The process of positioning the frames is called coordinating.

Stamps

When do we use Stamps?

If we need a frame more often
If we need to make a group/pack with other frames
If the component name comes from the XY file automatically

So if you need an inspection point just on a single location on the PCB, a stamp is not needed; it can just be a local
frame

Local Pictures & Stamp Pictures

Local picture: Picture taken from the PCB during placement of the frame. The picture in the Stamp List is Not
Activated (but the picture is stored in memory).
Stamp picture: Picture stored in the Stamp list. The picture in the Stamp List is Activated.

When using Local Pictures?

If just 1 piece of a stamp is on the PCB
If pictures of the same stamp differ too much depending on the location on the PCB. (e.g Wave soldering or Shadow
effects from tall components)
If we plan to use the picture replacement function
If we use Prototype Mode (quick setup using XY import and no debugging)

When using Stamp Pictures?

If we need a stamp more often on the PCB or from the library in the future
If we want to test filters, a stamp picture is easier because the picture is not replaced when moving the frame
When using Stamp Packs, it is not possible to use a local picture; even if the picture is not activated in the stamplist

Activating a Stamp picture

By a double click on the Stamp Picture in the stamp list, the Stamp picture is activated.

Remarks:
Before you can activate a stamp picture, an initial picture is already stored and visible in the stamp list. This picture is
from the moment of creating the stamp.

When:
Activating the stamp picture without the stamp selected in the Main window:
→ The initial picture becomes the stamp picture (the picture when the stamp was created)
→ The Stamp-Update symbol does not appear (and all frames still keep their original (local) picture until performing a
picture update).

Activating the stamp picture with the stamp selected in the Main window:
→ the picture of the selected stamp becomes the stamp picture
→ the Stamp-Update symbol appears to update all

High resolution (zoom) and Low resolution stamps

To create a stamp in High Resolution mode, draw the frame in “Zoom” mode.

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How to recognize a high resolution stamp:

The frame border is yellow (normal resolution frames are green)
Orange letters in the stamplist (normal resolution stamps are in black letters)

Remark:
It is not possible to change the resolution of a stamp after creation of the stamp.
A high resolution stamp has 4x more pixels and calculation time increases therefore.
Pixel related filter adjustments (Grid, Blur, Chase) are directly related to the resolution mode (e.g. Grid of 8pixels in
Zoom mode has a totally different grid size in Normal Mode (when comparing in mm)

Packs
A pack is also like a group of frames, but does not contain real frames but shortcuts to original stamps.
The shortcuts are vectors from the pack centre pointing at the original stamps.

If an original stamp is changed, all packs using that stamp are changed automatically.

Edit pack (double click to open and Enter to close)

To edit frames in a pack, double click the pack frame. Original stamps are appearing and can be edited. Close the
pack by the Enter key.

Pack Master for positioning

A pack has an assignable Master frame.

Activation
(Activate this function first in the Settings-Supervisor-Other-Extra-Follow Big Frame)
The biggest frame in the pack gets a green triangle in a corner, indicating this is the Pack Master.

Activate Individual stamps: Click Stamplist picture during 1 second. A green/blue background activates/de-activates
the Pack Master.
Activate All at once: ALT + Click Stamplist picture during 1 second.

Activate/De-activate in Debugging Stamplist: Toggle between and PACK and PacK by clicking the word PacK/PACK

Application
The Pack Master function, should always be used when checking solder joints. Only then, the presence of a meniscus
can be detected reliably, because they are linked to the component body.

From v350, the frame that becomes Pack Master can be selected (not automatically the biggest frame anymore).
Select the pack and use <SHIFT> + <TAB> to assign Master Status to a different frame.

Remark: never use a LeadGap frame as a Pack Master!

Change rotations of a Pack (in the stamplist)

The Default 0-degree angle of a Pack cannot be changed for the stamplist only; it will affect all these Packs in the program too.

When the pack orientation is wrong in relation to the CAD file, update the rotation for that pack and all packs in the program will be updated
automatically.
This updates the library orientation also, so for next time use of the library correction is not necessary anymore.

Change Rotation on the PCB and Stamplist:

Select the pack to be changed
Open the pack

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Select all frames inside the pack (using selection cursor and dragging)
Rotate all frames (by aR or aL) till they reach correct rotation.
Close the pack to update all packs and the library together.

Change Rotation of 1 pack (without changing the library)

Select the pack to be changed
Press aR or aL

Change Rotation of all the same packs (without changing the library) (From v350 onwards)
Select the pack to be changed
Select <ALT> - EDIT-FLIP/TURN- STAMP aR or STAMP aL

Groups(not often used)

A group is a group of frames. Each frame in the group is a copy of the original frame, with a different name, therefore
Example:
Making a group of 3 elements: Select all stamps & choose grouping (StampMenu or aG):
STAMP1 (component body)
STAMP2 (1st solder joint)
STAMP2 (2nd solder joint, using same stamp as 1st solder joint)

Automatically a new group is created with 3 new stamps:

GRP1: STAMP1.1 + STAMP2.1 + STAMP2.2
STAMP1.1 is a daughter (copy) of mother STAMP1
STAMP2.1 and STAMP2.2 are daughters (copies) of mother STAMP2

When changing settings of the mother stamp STAMP2, automatically daughters STAMP2.1 and STAMP2.2 will be
changed after “Update All” operation.
Remark:
Only updating if mother stamps are in the same folder as the new Group.
When changing settings of the daughter stamp STAMP2.1, mother STAMP2 and sister STAMP2.2 will be
NOT be changed after “Update All” operation.

Edit group (aE)

Use edit group to change positions and sizes of frames inside a group.

Find area
A group has its own find area. Each frame inside the group has its own find area too.
During finding, the find area of the group is used for all frames. The best matching frame fixes the group position. Then
the individual group frames use their own find area relative to the found group position.

Change 0 degree orientation of a Group in the stamplist

Place the group in the desired rotation for 0 degrees.
Edit group
Open the filter and press OK without changing anything in order to get the Stamp-Update symbol. Click this symbol.
While performing “Update All”, mark “Update an Angle” in the dialog box to store the new 0 degrees orientation in the library

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Differences Groups and Packs

A pack uses virtual frames. Basically, the frames inside a pack are shortcuts to the original frame in the library. The
frames inside a pack are the original frames their selves. This is why with packing, changing filter settings of the
original frame results in changing the filter settings inside all packs.

All differences:

Pack Group
Real frames X
Virtual frames X
Elements are originals X
Adding more frames later X
Position number (reference designator) internal frames X
Local pictures useable X
Search area individual frames X X
Search master frame and auto-position solder joints X
Present in MainStampLib v44 onwards X
Zero degree mark X
Zoom and normal frames together X
Directory level in the stamplist changeable X

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Component Identifiers
This e.g. Text Frame or Colour Test frame
Identifies correct type of components
Usually not for SMD capacitors

Large companies avoid inspection of identifiers because:

Time consuming in programming
False alarm sensitive
Main time consumer: chip resistors!
Good process flow and new PnP machines take out the neccesity

Example: Chip resistor identification

Many different values per PCB increase programming time when using identifier
Solution:
Use 1 Stamp (per size) to program all values
Use Base Resistor frames from MSL (MainStampLibrary) for position checking
Only few pictures needed for many values

Risk: If filter is too tolerant (e.g. green resistors present), Absence is not detected anymore!

If identification is needed, it is better to add an extra (identifier-) frame to the Pack later!

Cells
A Cell is a camera position (the Field Of View).
The Cell-Centre is the XY reference for all frames in that cell.

(Inside a cell the machine calculates in pixels, relative to the cell centre)

Therefore a correct pixel/cm value is very important for the accuracy of the machine when cells are changing.
All Cell rearrangements decrease the accuracy of the frame positioning

Avoid unnecessary cell changes!

Cell Optimisation by Cell menu

Select the cells to be optimised and select Cell Optimisation in the cell menu.
This optimisation algorithm reduces the number of cells, but does not create new cells.

Cell Optimisation by Edit menu after import XY data

Another optimisation algorithm can be chosen after importing XY data in the Edit menu. (Optimise Cells NC Data).
This algorithm can only be executed only once.
This algorithm creates new cells and can therefore cause more inaccuracies than the normal optimisation.
From version 3.4.1 this cell optimisation is not required anymore before doing another XY import!
Using the normal cell optimisation will also clear this requirement.

The Cell optimisation using the Cell Menu is usually the best optimisation.

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Centroid Data Import

Centriod data contains the centre coordinates of components. (also called NCD or CAD file)
This data is used by Pick & Place machines also.

Format
TXT Format (TAB Separated, by Excel, Save as text format)
CSV Format (Comma Separated Value, e.g. export from MS Excel)
(from SW version 334 onwards)

One text line for each component is defined as follows:

X,Y,W,Z,RefDes,Stamp
Explanation:
X X position value in 1/100mm or mm (depending on decimal point)
Y Y position value in 1/100mm or mm (depending on decimal point)

mm is used if XY data contains a decimal point

1/100 mm is used if XY data contains no decimal points

Example for 200mm:

200.00 = machine uses mm
20000 = machine uses mm/100

W Angle 0, 90, 180, 270 degrees (other values are ignored)

Z Feeder number (if not used, put 0 but NOT Blank)

(Remark: If no stamp name is used, this number becomes new stamp name)

RefDes Reference Designator. Component ID number

(e.g. C2413 Position number)

Stamp Component library name including category information

(E.g: c:tan:6032; Main category “c”, sub category “tan”, Name “6032”)

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Fiducial Markers

Single Panel PCB’s (Global Fiducials)

The system can use 2 Main fiducial markers per PCB:
MainMarker to define total offset
SubMarker (optional) to define rotation

If rotation correction is not needed, the SubMarker fiducial can be skipped.

Multi-Panel PCB’s (Local Fiducials)

Besides 2 Main fiducials for the whole PCB, the system can also use 2 local fiducial markers for each panel of multi-
panel PCB’s.

In this case the local fiducial marker has to become part of a block before multi-duplication (pitching)
In most cases only one local fiducial marker for multi panel PCB’s is sufficient (no rotation correction).

Important to know
The size of the frame around the fiducial mark determines is the main search area for the fiducial.
During inspection, the centre of the found fiducial will be moved to the camera centre and becomes the reference
position (all programmed locations are being offset/rotated relative to the found fiducial position).
The machines uses the surroundings of the fiducial for adjustment; not the fiducial itself, because the stabilty varies a
lot. Make sure that the surroundings are clear and that no other objects can disturb the detection.
During adjustment of the fiducial detection level, the red cross should be stable. If stable, the fiducial marker is
recognised properly.

DO NOT use the Fiducial Test button, because it changes the relation between fiducial positions and programmed
frames. All frames on the PCB can shift because of the use of this button.
As a consequence, do not use Virtual Centre button for extra accuracy, because it requires the use of the test button!

Use the correct algorithm for recognition (Circle, Square or “+”)

Use/Change Edging level if the contrast is too low for proper detection
Use a filter to improve visibility of the fiducial if needed
Use DOAL lighting (DL systems) for HASL based PCB’s. (pre-tinned PCB’s).

Picture fiducial
When the normal B/W fiducial algorithm cannot be used (e.g. fiducial marker not available or too unstable), a Picture
fiducial can be used.
When using, the matching picture is searched and its centre becomes the fiducial centre

How to set a picture fiducial?

Create a frame around the object that will be used as fiducial marker (like inspecting a normal object) but do not
include the search area in the picture.
Convert the frame to a fiducial marker
Set the filter needed for best recognition
Apply search antennas (using the right bottom Frame handle + CTRL key) to set search area. The size of the search
antenna determines the find area of the fiducial marker.
Now the frame has become a picture fiducial.

(to return to a normal fiducial marker, remove the search antennas again)

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