Optical Vision Systems Transform Microchip Handling Accuracy
In the high-precision world of the semiconductor industry, every micrometer counts. To ensure the exact, contactless positioning of even the smallest components, esmo AG, a leading provider of special machine engineering, automation technology, and semiconductor handling, relies on optical inspection technology from senswork in its Talos system series.
Microchips are becoming smaller, more sensitive, and more diverse, which also increases the demands on automated handling systems. This is exactly where Talos comes in: a handling system from esmo that significantly simplifies the testing process for microchips. The compact system can be flexibly adapted to different test environments and ensures reliable handling, whether from trays, tubes, or tapes.
Impetus Came From Practical Experience
A specific customer order provided the decisive impetus in 2021. A leading semiconductor manufacturer explicitly requested an optical alignment method in its specifications to be contactless and highly precise. “The reason for this is obvious,” explains Andreas Eberharter, Product Manager at esmo AG. “Mechanical systems repeatedly led to metallic particles in the process. With chips with edge lengths of less than a millimeter, this is simply not tolerable.” At the same time, the geometries of the components are becoming more complex, a challenge with sizes of only 0.8 x 0.8 mm in some cases.
The solution was obvious to esmo. It had already been in contact with senswork for many years through its esmo automation division. “Based on our positive experience working together, it was clear early on that senswork would take care of the image processing,” says Eberharter. “We never looked for alternative suppliers.”
Precise Positioning in Short Cycle Times
Together with senswork, esmo then developed a testing unit that is precisely tailored to the requirements of the handling system. The vision system detects the position and orientation of each chip with a resolution of 5 µm, even with tiny form factors. “It reliably detects even very small packages and works at a sufficiently high speed,” explains Eberharter. “With inspection times of around 0.3 seconds, we can easily meet our cycle time requirements of 14 seconds (with VisionAlignment).”
Another major advantage is the fully automatic calibration. The camera and handling system work continuously in exactly the same coordinate system. “That sounds trivial, but in practice it makes things much easier, especially when you have to change over frequently or handle different component formats,” says Eberharter.
Seamless Integration
Integration into the existing system went smoothly. “Installation is really simple and quick—just plug and play,” reports Andreas Eberharter.
Integrating senswork’s VisionCommander software into the existing esmo system environment was technically challenging due to the complex machine processes and interface requirements. However, thanks to close cooperation with senswork, a high-performance and reliable solution was developed.
“The support was and is there whenever we need it,” emphasizes Andreas Eberharter. senswork also responds quickly when new chip formats, changing component types, and new requirements arise. “The software is continuously being developed and adapted,” explains Eberharter.
In operation, the solution impresses with its high reliability and flexibility. The Talos system from esmo, which picks up, tests, and returns the microchips, has to be able to handle a wide range of chip sizes, from 0.8 x 0.8 millimeters to 5 x 5 millimeters. “This range is one of the biggest challenges in the industry. The fact that we can do this automatically and without contact is a major step forward – especially for our customers.”
Contactless Becomes Standard
By working with senswork, esmo was able to implement a future-proof solution for the optical positioning of microchips which is fast, efficient, and with impressive performance. Optical centering is now standard at Talos. The trend is clear. “Most customers now specify the contactless process in their specifications,” emphasizes Eberharter.
The success of the Talos systems speaks for itself. Demand is particularly strong in the US and Asia, with Europe in third place. “In Europe, Italy, France, and Germany are among our most important markets, but we are also receiving more and more inquiries from the Czech Republic,” says Eberharter.
Since Talos was launched in 2018, the machine manufacturer has been continuously developing the system. “We are already thinking about the next expansion stages,” reveals Eberharter. “Even smaller fields of view, larger components, higher computing power – with senswork’s vision systems, we are ideally positioned for this because they are scalable.”
For more information: www.senswork.com
