A Case Study: How Closed-Loop Stepper System Solves Step Loss
in Automated Optical Inspection (AOI) Systems
The Challenge: Step Loss in High-Load Applications
Client: A leading manufacturer in the semiconductor industry
Application: Automated Optical Inspection (AOI) Systems
In the semiconductor industry, precision is crucial for maintaining product quality. A prominent semiconductor manufacturer faced recurring motion control challenges in their Automated Optical Inspection (AOI) Systems using an open-loop stepper motor system. These challenges were mainly caused by step loss under varying load conditions, resulting in:
- Misalignment during critical inspections.
- Slower production speeds due to inconsistent torque.
- Increased rework and downtime from misaligned components.
As production speeds increased, the company needed a solution that would provide stable motion control and improve production efficiency without requiring a full upgrade to more complex systems.
The Solution: Closed-Loop Stepper Motor System
After evaluating several options, the manufacturer opted for SANMOTION Model No. PB, SANYO DENKI’s closed-loop stepping system. The key features that made SANMOTION PB the ideal choice included:
1. Closed-Loop Feedback to Prevent Step Loss
The SANMOTION PB system uses an integrated closed-loop feedback mechanism that continuously monitors and adjusts motor performance in real time. This system eliminates step loss, ensuring accurate positioning, even in environments with fluctuating loads.
2. High Torque at High Speeds
3. Cost-Effective Performance Boost
The manufacturer was able to improve the motion control system’s efficiency without committing to a full system upgrade, making SANMOTION PB a more cost-effective solution. It offered high precision and stability while being more affordable than other high-end systems.
4. Seamless Integration with EtherCAT
The Results: Increased Efficiency and Accuracy
After switching to SANMOTION Model No. PB, the manufacturer saw a remarkable improvement in the performance of their Automated Optical Inspection (AOI) Systems:
- Eliminated step loss, ensuring flawless inspections and reducing errors.
- 20% faster inspection speeds, significantly increasing throughput.
- Improved integration with EtherCAT and other automation systems, leading to more reliable operations.
- Reduced energy consumption and lower heat generation, leading to a more stable environment.
With SANMOTION Model No. PB, the company was able to enhance production efficiency and maintain the high precision required for semiconductor manufacturing.
For simpler motion tasks, SANMOTION F2, the open-loop stepper system, remains a cost-effective option, but for high-precision industries, SANMOTION Model No. PB is the key to efficiency, reliability, and superior control.
Contact SANYO DENKI to find the best stepping motor solution for your automation needs!
