Vibration Reduction in Automated Optical Inspection (AOI) Machines: A Comprehensive Study

Objective: Achieving Repeatability with Positioning Precision < 0.3 μm

Abstract

This study focuses on identifying and addressing vibration issues in an Automated Optical Inspection (AOI) machine designed for high-speed, high-precision operations. Using RecurDyn’s Multi Flexible Body Dynamics (MFBD) technology and the MachineTool toolkit, we analyzed vibration sources and optimized the machine’s design to achieve positioning precision below 0.3 μm. The findings highlight the effectiveness of simulation tools in improving the stability and performance of AOI machines while streamlining the development process.

Automated Optical Inspection3

Automated Optical Inspection Machine

Introduction

AOI machines are critical in inspecting printed circuit boards (PCBs) during manufacturing, ensuring quality control and operational efficiency. To meet the industry’s demand, these machines must maintain extremely precise sensor positioning over numerous operational cycles. Traditional prototyping methods are resource-intensive and challenging for engineers with limited experience. This study leverages RecurDyn to address these challenges, enabling precise modeling, simulation, and refinement of AOI machines.

Automated Optical Inspection1
Automated Optical Inspection2

Methodology

Analytical Foundation

The initial analysis focused on understanding vibration behaviors and their impact on positioning precision.

Simulation Process
The AOI machine was modeled and analyzed using RecurDyn with several specialized features:
    • Beam Force Modeling: Bolts were simulated as beam forces to represent stiffness with high accuracy and computational efficiency.
    • Linear Guide Design: RecurDyn/MachineTool allowed the detailed creation and simulation of the linear guide system.
    • Motor Dynamics: Real-world motor behavior was incorporated using drive curve data to simulate operational dynamics.
    • Flexible Body Integration: Key components were modeled as flexible bodies to replicate vibration accurately.
Simulation Execution

Dynamic simulations were performed under realistic operating conditions, focusing on identifying vibration sources and evaluating machine stability.

Validation
Results from simulations were cross-verified with empirical data to confirm the accuracy and reliability of the virtual model.

Results

The simulation outcomes identified and mitigated vibration sources, enabling the AOI machine to achieve sub-micrometer precision. Key findings include:

  • Improved design stability through the reduction of vibrations.
  • Efficient machine refinement by engineers with minimal prior experience using RecurDyn’s intuitive toolkits.
  • Reduced development time and costs by minimizing reliance on physical prototypes.

Discussion

This study demonstrated the effectiveness of RecurDyn’s MFBD technology and MachineTool toolkit in optimizing AOI machine design. By addressing vibration issues early in the development process, the simulation approach facilitated the creation of a stable, high-precision machine with less dependency on physical testing.

Conclusion

RecurDyn enabled a simulation-driven solution to improve AOI machine performance, achieving precise, repeatable sensor positioning below 0.3 μm. The validated simulation model offers a cost-effective and efficient alternative to traditional design methods, empowering engineers to innovate confidently and effectively.