Technical White Paper of SD-FAI6000V Intelligent First Article Tester

I. Product Positioning and Industry Value

II. Core Product Advantages

III. Core Functional Features

1. Dual-Map Visual Inspection

• Panoramic Map: Displays the distribution of all components on the PCB board and the inspection progress, clearly presenting the overall inspection status;

• Local Enlarged Map: Magnifies the details of tiny components (such as resistors of 0402 specification) to ensure that employees can clearly compare the physical silk screen with standard parameters and avoid misjudgment caused by visual errors;

• Auxiliary Function: Cooperates with voice broadcast prompts (such as "Currently inspecting R117 resistor" and "C84 capacitor inspection PASS") to further improve inspection efficiency.

2. Automatic Generation of Inspection Program in Three Minutes

• Multi-Format File Import: Automatically identifies the customer's BOM table (Excel/text document), coordinate file and PDF position map, and is compatible with the BOM format specifications of different customers;

• Intelligent Rule Definition: Exclusive BOM analysis rules can be set for different customers and different products to adapt to diversified production needs;

• Optimal Path Planning: After the program is generated, it automatically selects the optimal inspection path and marks it with a dotted line in the PCB drawing to avoid repeated movement of the inspection fixture and shorten the inspection time.

3. Automatic Identification of Component Silk Screen/Direction/Polarity

• Coverage of Multiple Component Types: Supports automatic identification of components such as IC chips, diodes, triodes and resistors with characters;

• Core Technology: Adopts OCR (Optical Character Recognition) technology, and resistors of 0402 specification and above do not need to make component templates, and silk screen inspection can be completed with one click;

• Polarity Judgment: Through optical comparison technology, it automatically identifies the positive and negative poles of diodes and the Pin direction of IC chips, avoiding the burnout risk caused by reverse polarity.

4. Automatic Judgment of Inspection Results

• Automatic Data Collection: The scanner obtains the appearance image of components, and the bridge collects parameter data such as resistors, capacitors and inductors;

• Intelligent Judgment: The system compares the measured data with the standard parameters of the BOM and automatically outputs the results of "PASS (qualified)" or "FAIL (unqualified)", avoiding manual subjective judgment errors;

• Abnormal Prompt: The FAIL result is marked with the abnormal type synchronously (such as "resistor value exceeding standard" and "reverse polarity"), facilitating employees to quickly locate problems.

5. Fully Automatic Inspection Report Generation

• Full-Dimension Data Presentation: The report includes key information such as product number, work order number, production line, inspection time, total number of components, number of PASS/FAIL, pass rate and inspector, meeting the traceability requirements;

• Multi-Format Export and Sharing: The report can be exported in PDF format, supporting archiving, printing or direct sending to customers/quality departments via email;

• Report Example: The inspection report of a certain product shows that "the total number of components is 64, the number of PASS is 64, the pass rate is 100%, and the inspection time is 1 minute", with clear and traceable data.

6. DCT Intelligent Auxiliary Inspection

• LED Inspection: Through forward and reverse power-on lighting tests, it automatically judges the direction and luminous performance of LEDs;

• Diode Inspection: Automatically detects the forward and reverse voltage drop, distinguishes the polarity of diodes, and avoids circuit failures caused by reverse installation.

7. Multi-Dimensional Component Query and Retrieval

• Retrieval by Status: It can filter "uninspected components", "NG components" and "inspected components" to avoid missed inspection;

• Retrieval by Attribute: Supports retrieval by part number, location number and component type (such as resistor, capacitor, IC), for example, "find all capacitor inspection records of part number 1210030015";

• Historical Data Tracing: The retrieval results simultaneously display the inspection time, measured parameters and judgment results, facilitating quality analysis.

8. Seamless Connection with ERP/MES Systems

• Two-Way Data Interaction: The inspection report can be automatically uploaded to the MES system to update the production progress and quality data synchronously;

• Manual Capture Support: If the customer's system does not support automatic upload, the report data can be manually captured through the system interface to ensure the closed-loop of production data;

• Management and Control Value: Helps enterprises realize the full-process visual management and control of "production-inspection-quality", facilitating management to grasp the production status in real time.

IV. Detailed Technical Parameters

V. Application Scenarios and Customer Value

1. Core Application Scenarios

• Multi-Variety and Small-Batch Production: Such as automotive electronic components (with a batch size of 500-1000 pieces per order), which require frequent product model switching. The equipment can quickly generate inspection programs to adapt to flexible production;

• High-Precision Requirement Scenarios: Such as PCB boards for medical equipment (needing to meet FDA certification), which have high inspection precision requirements. The equipment can avoid manual errors and ensure compliance;

• Large-Scale Mass Production Scenarios: Such as consumer electronics (mobile phone motherboards, tablet PCBs), which require daily inspection of 50-100 batches of first articles. The equipment can greatly improve inspection efficiency and avoid production line shutdown and waiting.

2. Customer Value Implementation

• Efficiency Improvement: The first article inspection time is shortened from 25 minutes per batch to 4 minutes per batch, and 30 more batches of first article inspection can be processed per day, with the production line utilization rate increased by 15%;

• Cost Reduction: It replaces 3 manual inspection positions, saving 400,000 RMB in annual labor costs, and the equipment investment can be recovered in 6 months;

• Quality Improvement: The defective rate in mass production is reduced from 0.8% to 0.25%, reducing the annual loss caused by defective products by 280,000 RMB;

• Compliance Improvement: It meets the IATF16949 automotive industry standard and successfully passes the factory audit of main engine plants (such as BYD and Tesla).

VI. After-Sales Service and Technical Support

• Installation and Commissioning: Free on-site installation and commissioning, and on-site training for operators (1-2 days);

• Warranty Service: 1-year warranty for the whole equipment, and 2-year warranty for core components (bridge, scanner);

• Maintenance Support: 7*24-hour technical hotline, fault response within 4 hours, on-site service within 24 hours in the Pearl River Delta region, and on-site service within 48 hours in other regions;

• Software Upgrade: Free 1-year software upgrade service is provided, and annual service packages can be selected for subsequent upgrades (the cost is 5% of the total equipment price per year);

• Spare Parts Supply: Spare parts warehouses are set up in Shenzhen, Shanghai and Suzhou, and common spare parts are delivered within 24 hours.