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Production PCB Most acceptability criteria are evaluated on the production PCB by visual or dimensional means. Visual inspection is typically done under low magnification by human operators. Although the human eye is very capable of catching inconsistencies in the circuit patterns and surface materials, it is not always consistent and can allow nonconforming attributes to slip through. Because of this, many companies have turned to using automated optical inspection (AOI) machines to check pattern integrity, consistency, and dimensions. AOI provides a much more consistent evaluation of circuit geometry than the human eye, but is a slower and more costly option. Many visual inspection attributes have dimensional attributes attached to them. It is important to note that magnification for inspection of dimensional attributes should be sufficient to make an accurate measurement to determine acceptability.

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We need a starting point for the counter because we will be using the system counter to measure various cycle times and pulse widths. We do this by setting the starting period count because we will set the final period count by adding the current counter value to the cycle time:

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Test Coupons and Patterns For testing purposes, there are several reasons to utilize test coupons and patterns that are representative of the PCBs rather than the PCBs themselves The downside of using coupons is that they take up space on the manufacturing panel and therefore increase the overall cost of the PCBs Also, the test coupons are not actually part of the PCB and are typically placed at the edges of the production panel, where production attributes may be different from the production panel This can cause the coupons and patterns to reflect different attributes than the PCBs they are attempting to represent It is very important to take steps to ensure that the test coupons and patterns are actually manufactured in a manner that is representative of all the attributes of the PCBs associated with them.

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It is important to ensure that any holes in the coupon are drilled with the same tools and parameters as those on the corresponding PCB Coupons and patterns are typically used in situations where using a PCB for testing would either not provide the information required or the PCB would have to be destroyed in order to get the information Coupons and patterns can be used for microsectional analysis, electrical measurements, environmental simulation, and reliability evaluation See Fig 5111 for an example of test coupons taken from IPC-2221 (Unless noted otherwise, figures in this chapter are courtesy of the Association of Connecting Electronics Industries [IPC], and are taken from the publication IPC-600, Acceptability of Printed Circuits These figures can be found in that document under the headings noted in this chapter for specific topics Figures credited to the author of this chapter are taken from presentations made by him.

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Other figures are from the sources noted in the captions For further details on design and placement of coupons, see IPC-2221).

Microsection Microsectioning the holes from a PCB provides a cross-sectional view of the construction of the PCB. Microsectioning a PCB with a design that removes nonfunctional pads makes it virtually impossible to inspect all the interconnecting layers in the hole, so microsections are typically done on associated and optimized coupons containing PTHs that contain pads on all the layers. Microsectioning PCBs requires great skill, as the PCB contains both hard and soft materials and the area of interest is very small. Improper microsection technique can either create or hide anomalies. For example, interconnection separation can be created or hidden by improper techniques.

FIGURE 51.1 Quailty conformance test coupons taken from IPC-2221. (Courtesy of IPC.)

With all this in place, the code in Program 7-1 will give us a fixed pulse width of PulseWidth. The pulse width is set as a negative value because we will be adding 1 from the counter at each cycle of the clock to work it to zero.

An inspection lot consists of all the PCBs fabricated from the same materials, using the same processing procedures and constructions and produced under the same conditions. Differing PCBs can be combined to form an inspection lot, but then they must all be submitted together for inspection. It is the PCB manufacturer s responsibility to maintain traceability for all the PCBs in an inspection lot along with any corresponding test coupons that were separated from the production panels. The success of inspections greatly depends on how the inspection lot is formed. The goal of forming the inspection lot for a particular attribute is to allow, if applicable, a smaller sampling of the inspection lot to be representative of the entire lot. In forming inspection lots and sampling groups, the methodology for producing the attribute and the consistency of that methodology or process must be taken into consideration. Some PCB processes are done in batch form and others are done on a panel-by-panel basis. Understanding process techniques is critical in forming inspection lots and sampling groups that are representative of the product.

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