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Securing IP and Lowering Costs by Bringing Mission-Critical Programming In-House


By Scott Bronstad, Marketing Communications Manager, BPM Microsystems O


ften cited, Moore’s Law states that integrated circuits double in both speed and number of


transistors roughly every two years. As programmable devices become smaller, denser and more complex, most machines that program those de- vices have become more expensive and require experienced technicians to op- erate, maintain and troubleshoot. The drawbacks to outsourcing


programming are many, including added cost, minimum orders, long lead times, and reprogramming or scrap when data files change. Another dan- ger is protecting IP. Once the source code leaves the factory, it is vulnera- ble to theft. Due to current market


conditions, companies are increasing- ly concerned about interruptions in supply chain, especially for compo- nents sourced from Asia. Until recently, it was not feasible


for most OEMs with significant pro- grammed device requirements to jus- tify the cost of bringing programming in-house. Automated programming systems were expensive and complex to set up, run and maintain.


Birth of APS BPM Microsystems began mak-


ing EPROM programmers in the mid 1980s. The company’s founder, Bill White, was a student at Rice Universi- ty, working on his degree in electrical


engineering. He needed a way to get his code


on a read-only chip, and discovered there was not a good way to do so. So, he built his own programmer. While he was living in the dorms, he started selling his new programmer, the EP-1, by mail order, and BPM Microsystems was born. BPM launched its first automat-


ed programmer in the mid 1990s, the BPM 4100 — the only universal fine- pitch automated pick-and-place pro- gramming system at the time. Com- pared with today’s machines, it was slow and difficult to set up (and oper- ated in DOS). But, compared with the single-purpose machines of its time, the 4100 revolutionized device pro- gramming by combining universal programming technology with fine- pitch handling capability.


Z-Axis Teach The “holy grail” of consistent au-


tomated programming results is the z- axis teach. There are three axes on an automated handler: x, y and z. X (hor- izontal) and y (vertical) are easy — a downward facing camera with a bomb- sight allows for precise placement on the center of a device. The z (up/down) is, by far, the


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most difficult and the most important. Both the pick and place locations, if off by less than the width of a human hair, can cause major problems. Man- ually adjusted x-teach can go badly in two ways: pick (or place) too high can cause misalignment of the device; place (or pick) too low, where the noz- zle can come in contact with the de- vice, may cause micro-cracks. Devices with micro-cracks usually pass the ini- tial test (green light), but can oxidize the sensitive metal film, causing de- vices to fail in the field. BPM has solved the z-axis prob-


lem with a patent-pending solution called WhisperTeach™. It utilizes hardware and software to turn the de- vice nozzle into a sensor. Without coming into contact with the device, the automated system detects the height of the device to within 15 µm (four times finer than a human hair), and automatically completes the teach in under eight seconds. A trained technician, although


not as accurate as WhisperTeach, can teach a single location in about a minute. On a single job set up, the dif- ference in time is dramatic. Whis- perTeach set up is usually around five minutes, manual teach can take up to an hour. When adding the loss of pro- ductivity to the reduction in precision, things can get dicey quickly. Regardless of which programmer, pick-and-place


systems are incredibly repeatable. If the teach is off by a small amount, pick- and-place will be off as well. Since about 2010, the strongest


market segment for automated pro- grammers has been automotive sup- pliers. The automotive industry has an ever-increasing need for program- ming as cars become more complex and technology-driven. They also often require 3D in-


spection and laser marking to ensure consistent quality and to track inven- tory. Big projects, with millions of pro- grammed devices, make device pro- gramming in-house a no-brainer. Smaller OEMs, while perhaps


having many of the same needs as the automotive industry, are often con- strained by limited resources. As pro- gramming needs outgrow the ability to produce on manual systems, the on- ly option is to outsource to program- ming houses or ship component manu- facturing offshore.


Mitigating Risk OEMs recognize the risk of out-


sourcing critical components, such as programmed devices, to offshore sup- pliers. They are now looking more closely at options that reduce their re- liance on forces beyond their control, in a way that lowers costs and speeds time to market. BPM has a history of innovation,


as well as a reputation as a “luxury brand” in device programming — fea- ture rich and pricey — especially when compared with low-cost ma- chines from Asia. That changed with the launch of


the 3901, a low-cost, full-featured au- tomated system with vision centering and universal support. The 3901 has a maximum configuration of 16 device sockets and starts at under $90,000. Within 10 days of its launch in Oc-


tober 2019, the first 3901 was sold to a telecommunications OEM in the north- east U.S. The second soon sold to a heavy equipment manufacturer in the midwest. Both companies needed an af- fordable system that can supply their catalog of programmed devices to their lines. The 3901 quickly became the fastest-selling automated system in the company’s 35-year history. Equipment manufacturers, espe-


cially those in North America, Europe and the Middle East, finally have a lower-cost option for their device pro- gramming needs, without sacrificing


quality and capability. Contact: BPM Microsystems,


15000 Northwest Freeway, Houston, TX 77040 % 713-351-5521 E-mail: scott_bronstad@bpmmicro.com Web: www.bpmmicro.com r


June, 2020


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