Tape Feeder Unit an automatic semiconductor packaging module

Electronics became every day more and more widespread in our life, all technology devices use electronic components, from the smartphones to the safety related instruments, therefore the production and testing of semiconductor increases every day, one of the most common semiconductor transport method is seal them into reels, this is the intent of the Tape Feeder Unit TFU. The thesis aim is explain all the issues and solutions adopted developing an automatic handler module responsible for packaging the semiconductor or microelectromechanical systems (MEMS) already tested into reels and then optimize the automation process in order to meet the demanding requirement in terms of reliability, flexibility and quickness. This system is conceived for process one device in just 225ms according to the faster and faster semiconductor production and testing machines. The research describes the peculiar characteristics of the system and outlines the technical methods and choices adopted during the project development pointing particular attention to the optimization of the control loop architecture. The TFU apparatus is formed by five sub-units, which they must operate synchronously for that reason to guarantee the correct working process a PLC Master controller is chosen for supervises the whole mechanism. The Master controller communicates with the modules and drives exploiting the Ethercat communication protocol, which is one of the fastest way to transmit all the data throughout the system. The first topic treated is the mechanical configuration and features, addressing the pro and cons of the possible different configurations. After that, the vision system and the pneumatic layout have been explained; focusing on the quality and goal reached developing that. From there, I consider the electronic needed for manage all the input and output signals coming from the sensors deployed all over the system for sensing the modules status. Finally, I directly analyze and optimized the control loop of the motor accounted of manages the carrier tape flowing, called Indexer unit, this for enhancing the motor performances and for respect the rigorous takt time. The control loop optimization has been tackled exploiting the drive software, which permits, to change the control loop gains in order to improve the stability and the responsiveness of the module, an accurate analysis of the obtained open loop gain has been tackled, with the aim of increase the control loop efficiency and adapt it to the requirement, then a step input has been supplied to the motor in order to evaluate the system response and ensure the requirement fulfilment, as last phase the computed control loop has been directly implemented on the final system in order to analyze the achieved performances.