[Case Study] Board Inspection for Power Generation and Power Systems
TAKAYA APT Series
Please utilize Takaya's flying probe tester for substrate inspection in power generation and power systems.
By combining electrical testing using APT with AOI, which is difficult for discrete components and hand-inserted parts, we achieve the high quality standards required for power generation and power system boards, providing an efficient inspection system. 【Implementation Results】 - Conducted implementation verification focused on discrete components, achieving quality assurance for power system boards that require high reliability. - Realized 100% inspection on boards including power lines and hand-inserted components. 【Challenges Faced by Customers】 Limitations of AOI Inspection: While AOI (Automated Optical Inspection) excels at inspecting surface-mounted components, it has limitations in the following areas: - Difficulty in inspecting hand-inserted components: It cannot sufficiently verify the quality of the implementation of power lines and large discrete components. - Insufficient confirmation of component position and polarity: AOI cannot accurately confirm electrical characteristics, leading to the risk of missing incorrect insertions or polarity issues. Risks During Power Supply: Defective components or miswiring in power lines can lead to damage to the board or destruction of components. Particularly, if the quality assurance for discrete components is inadequate, the risk of overheating or short circuits increases. Generation of Waste Boards: If the board is damaged during power-on testing, the disposal of defective boards occurs, leading to increased costs.
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**Benefits of Introducing Flying Probe Testers** Complementing AOI with Electrical Inspection: Electrical inspection of hand-inserted components and large discrete components that are difficult to inspect with AOI using APT (Flying Probe Tester). Precisely check the component placement and polarity on power lines, as well as the presence of shorts and bridges, to identify defects before power is applied. High-Reliability Quality Assurance: By inspecting electrical characteristics, prevent misinsertions and polarity issues. Prevent defects on the board before power testing, reducing the risk of board damage. Reduction of Discarded Boards: Minimize component damage and board destruction that occur during power testing. By eliminating defective boards, reduce disposal costs and improve product yield. Support for Discrete Components: Inspect the physical condition of hand-inserted components and large parts, maximizing inspection coverage through the combined use of AOI and APT. Flexibly accommodate large boards and complex circuit designs.
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**Effects of Implementation** Pre-power-on inspection to prevent defective outflow: APT conducts detailed inspections of power line defects that are often overlooked by AOI. Identifying issues before power-on prevents damage to the circuit board. Reduction of production costs: Reduces waste due to circuit board damage, lowering overall manufacturing costs. Minimizes the effort required for re-inspection and defect handling. Achieving high safety: Enhances safety during power-on for power system circuit boards. Establishes a quality assurance system that meets the high reliability standards required for power generation and power systems. **Application Examples** Power generation system circuit boards: Inspection of power lines for high voltage compatibility. Electrical quality assurance for manually inserted components (relays and transformers). Power distribution device circuit boards: Inspection of power lines for circuit boards that include large discrete components. Prevents shorts and bridges from occurring in advance. Battery management system circuit boards: Component placement and polarity inspection aimed at preventing heat generation during power-on.
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Founded in 1894 as a textile company, Takaya Textile expanded and established its electronics division in 1966, beginning the assembly of transistor radios. Currently, in addition to contract manufacturing services (EMS) related to electronic devices, the company actively manufactures and sells in-circuit testers (printed circuit board inspection devices), RFID-related equipment (technology that enables information exchange through short-range wireless communication from IC information tags), and engages in IT consulting and system solutions, among various electronics businesses both domestically and internationally. We will continue to evolve as a corporate group that contributes to the development of society, with textiles and electronics as our two pillars.
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