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Automatic High-Precision Automated Assembly & Inspection for Semiconductor Clock Modules | CAC Systems

Overview: Transitioning from Manual to Autonomous Production

Creative Automation Company (CAC) engineered a custom turnkey solution for a global semiconductor manufacturer to transition a high-stakes manual assembly process into a fully automatic, high-throughput environment. This project focused on the precision integration of semiconductor chips, quartz crystals, and power-cell batteries into synchronized computer clock modules.

The Challenge: Precision Scaling & Static Mitigation

The assembly of these sensitive electronic components demanded the utmost in micron-level repeatability to ensure electrical integrity across the substrate. The client faced three primary obstacles:

  • Precision Demands: Manual handling could not maintain the sub-millimeter tolerances required for the lead-forming and soldering stages.

  • ESD Risks: The manual environment increased the risk of Electrostatic Discharge (ESD), which threatened the viability of the semiconductor chips.

  • Labor Bottlenecks: The manufacturer required a streamlined solution that could substantially increase UPH (Units Per Hour) while reducing direct labor requirements and human error.

The Solution: Dial-Type Automatic Transfer & Integrated Testing

Our engineering team developed a multi-station rotary indexer (Dial-Type) system that automates the entire lifecycle of the clock module assembly. This system eliminates manual contact and utilizes high-speed mechanical synchronization:

  • Automated Component Feeding: High-speed vibratory bowls and pick-and-place units orient and load chips and crystals with zero human intervention.

  • Precision Lead Forming: Integrated forming tools shape the quartz crystal leads to match the semiconductor chip’s footprint perfectly.

  • Active Voltage Verification: The system performs an in-process battery test prior to placement, ensuring only viable components proceed to final assembly.

  • Non-Shorting Soldering: A proprietary soldering process connects the leads without compromising the internal battery circuit.

  • 100% End-of-Line Inspection: Every module undergoes a final functional test and automated sorting before being palletized for shipping.

  • The Result: Measurable ROI & Quality Assurance

    By implementing this automated assembly and inspection system, the manufacturer achieved:

    • Zero-Defect Production: 100% automated inspection eliminated the possibility of human error during the quality control stage.

    • High-Volume Scalability: Significant increase in production capacity to meet global semiconductor demand.

    • Operational Efficiency: Drastic reduction in labor costs and a stabilized, predictable production schedule.

The CAC Advantage: Custom Engineered Solutions for Precision Manufacturing

In the world of electronics manufacturing, standard integration often falls short of the rigorous tolerances required for long-term viability. At Creative Automation Company, we specialize in Custom Engineered Automation designed to bridge the gap between complex manual assembly and fully autonomous production.