Dana Lee Church - Engineering Capabilities r14

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Dana Lee ChurchLaser Systems, Software and Integrated Automation SolutionsDana Lee [email protected]: 443-13-8686https://www.facebook.com/teosysengineering/#Systems & Software: 410-989-6420https://www.facebook.com/SystemsSoftwareEtc/#

TeoSys Engineering LLC ConfidentialTeoSys Engineering LLC Capabilities & Products

Page #TeoSys Engineering LLC ConfidentialTeoSys Engineering LLC Capabilities & Products

What Drives Us What we like to doFinding new and innovative ways of applying lasers and laser solutions to resolve difficult, customer driven applications.

Finding and developing robust solutions where others could not.

Demonstrating lasting and persistent value of our services to our clients and customers.

Seeking to obtain complete customer satisfaction while maintaining a nurturing, creative and fulfilling work environment.

Currently installed customer base.

Over 60 micromachining systems and software installed globally!


Custom TeoSys user interface software aids the operator in making small marks without the knowledge of a CAD system interface.

Capabilities Micro Marking in the Very Small

Excimer marking using line widths down to 5 microns. Spot overlap up to 0.33m in pulse synchronized output mode. This means that we are guaranteed a spot at every 0.33ms.

Small feature micro marking on transparent media.


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Custom Systems - LMS-1500, IR / Green Micromachining System (532nm and 1,064um)

Semi-Automatic Parts HandlingHigh Speed Precision Rotary


Applications Channel Drilling

Custom Motion Systems and FixturesChannel drilling in steel bar stock using 532nm, frequency doubled Nd:YAG laser.

Channel widths of 25um through 500ums which spans the gamut between micromachining and traditional mechanical machining. (right)

Tube cutting in proprietary pattern. (below)





Custom Laser Systems LMS 5000 12 Axis Automated 2 Part Type Drilling System

Automated Part Loading , Drilling, Measurement and Ejection in Laser Drilling SystemLoads and Orients up to 6 Different Part Types Custom designed system to drill 50um (10um 200um) holes in steel mini-cups comprised of mostly nickel.

Laser is an 1064nm Nd:YAG frequency doubled to 532nm.

Automation consists of the following: feeding mechanism; transfer system; pick and place tool; and a main drilling rotary index plate with 8 individual stations for part loading, drilling, hole measurement and pass/fail ejection.

Integrated fiber sensors for part orientation positioned on 1st, 16 part rotary table

In-house designed hole diameter measurement device using 1 photodiode and 2 photodetectors

System is integrated via distributed control software with master control program providing for a simplified human machine interface (HMI) for non-technical operators.


1. Automatic part loading via rung system which gathers parts from a bin with a single orientation.

2. Parts are rotated while facing upwards and roll down a track where they are placed onto a plate which separates each part from the other3. Parts are picked up via vacuum tool and placed onto the indexing plate at the loading station4. Parts put onto the index plate in the appropriate alignment

Each part type has a different drill location

The part is rotated by the index plate to the drill station where it is laser drilled

5. After drilling, the part rotates to the measurement station where it is measured6. Based on the measurement, the part is then ejected into a good or a bad binLMS-5000 Part Automation System


Automatic generation of tool cut path programs based on user specified parameters including the following: Part type Hole Diameter Stage Speed Trepan - Number of Passes Laser Energy Real time display of system status bits Real time display of drilling operation Operational modes such as dry run and full auto drill

In-Situ Measurement of the machining features (hole diameter)

Vertical distance between calipers, horizontal distance and point to point distance between horizontal and vertical intersecting lines

Bright field, dark field illumination, top and bottom illumination

Camera switching for operator feedback of multiple automation stations Motion system stage feedback for operator (axis position)

Automatic calibration (in-situ) of the optical (flow) measurement system which measures hole diameter

Automatic statistical process control display and recording to status files

LMS-5000(Software & Control)


Custom Systems Software LMS-5000 Integrated Automatic Inspection

Creation of 3rd order regression curve for calibration of photo detector with actual hole diameters to create the relationship between diameter and application flow rates. Ability to take real time measurements from instrument Status and feedback during operation Diameter measurement via light extinction sensor made of dual laser diodes / photo detector combination Measure hole diameters with 1 micron resolution from 20um through 75um Basic hole positional information within 25um of true position Diameter measurement calculated within 500ms and position measurement within 1 second.

Incorporation of an Ophir Profilometer to measure beam profileIn House Developed Measurement System (OFT)


This is an example of the second level interconnect for the LMS 5000 12 Axis Part Drilling Laser System. It depicts the 3 major control systems (motion systems) that make up the entire parts automation system. Each arrow that interconnects the major nodes denotes a digital or analog signal which I designed using the digital and analog IO of the system motion control boards in order to communicate the separate system states to each other node. The system states are event driven so that no race conditions occur in either the axis movement or the timing of the main controlling index plate which performs the loading, drilling, measurement and ejection of each of the parts.Each motion system node has a motion controller board controlling 4 stages.

Systems Engineering 12 Axis Motion Control & Laser Part Drilling System


Systems Engineering 12 Axis Motion Control & Laser Part Drilling SystemThis is an example of the hardware interconnect for the LMS 5000 12 Axis Part Drilling Laser System.

It depicts the 3 major control systems (IO between motion systems and peripherals) that make up the entire parts automation system.


Standard Systems LMS-2500 - Heavy Duty Excimer Laser SystemHeavy Duty T300, 193nm Deep UV 300 Hz HighSpeed Excimer Laser with Power Output of 14-18mJ per pulse at 100 Hz.2x4 1/4um accurate precision stages (X, Y, Z, U)Automated Gas Handling. SystemTwo visible zoom levels (1 co-axial w/laser beam)Integrated UV and Visible Imaging with projected reticule for focusingFour Axis monochromatic (red) illumination systemAutomatic programming of focus (X Axis)


Standard Systems LMS-550 Desktop Excimer Laser System193nm Deep UV Laser Source Fully IntegratedDesktopUser Friendly

Heavy Duty T20 Laser.193nm Deep UV 25 Hz Excimer Laser: 7 - 10mJ per pulse at 100 Hz.2x1 1.52um accurate stages (automated X, Y / manual Z Axis).1 5um accurate manual Z-Stage.Manual Gas Handling.Software fully integrates motion control, laser and text & DXF graphics data entry, scaling and translation on work surfacePortable Version LMS-550


Standard Systems LMS-650 Professional Excimer Laser System

193nm Deep UV 100-200 Hz Excimer Laser10 - 12mJ per pulse.2x2 1.52um accurate stages (X, Y automated Axis).1 2um accurate manual z-stage.Manual Gas Handling.Integrated UV and Visible Imaging with projected focusing reticule.Two Axis monochromatic illumination system (Top and Bottom)Software interface allows automatic entry of vector based graphics and text (auto converted to DXF vectors)

Exclusive Excimer System of Harvard Robotics Laboratory


5 Axis Fully Automated Wire Stripping

Light Duty T20, 193nm Deep UV 30 Hz ExcimerAblation of 3-5 um of polyimide surrounding 10um steel wireFully automated X, Y, Z, U & F StagesABLATION - U Axis rotates fixture; F Axis rotates spool; Y Axis advances wire simultaneously for polyimide ablation w/o breaking wireY Axis is advanced during ablation for (10 microns) Software saves picture of ablated wireCUTTING - Z Axis linearly refocuses 15X objective for wire cutting process (post ablation)Fixture moves UP/DOWN by X Axis 15 microns to for wire cut process. Wire drops in bin.X & Y steppers controlled via Galil 1822 PCI motion controller; U, Z, & F Axes controlled using All Motion boards


8 Axis Stepper - Automated Wire Stripping


Generic Rapid Release Windows8 Axis Stepper - Automated Wire Stripping


Standard Systems Software for Graphics, Text & 2D Data Matrix Inscription Step wise execution to guide user and avoid all user faults Above example is for 2D Data Matrix inscription. Text is entered in the textbox and the software automatically converts the text to a 2D Data Matrix which can then be scaled and translated on the work surface so as to omit mistakes The work surface is not captured in this capture program because I am using the hardware memory for fast display onto the PC live video window Application includes all laser control via the rotary switches and toggle buttons Text & graphics dimensions (in microns) are displayed for informational purposes Motion system stage feedback and axis positions are displayed in real time

Below is a close-up of the motion program which is auto-generated by the application softwareThe bottom display textbox acts as the programs console. It displays any information that the motion control program instructs.In machine vision mode, dimensions are displayed.


Aerotech, 2 AS3005 amplifiersPC witch DR500 with 40V-40V split bus, 2 AS 32020 h Aerotech PCI U500 Ultra w/PSO output and live video frame grabber (live video integrated into Control Software)In-situ video microscope software for in-situ measurement (Measurement Software application allowing in-situ feature measurement)Aerotech ATS 150-150MM lead screw stages X & Y ( 6 inch travel)Aerotech ATS 100-100 MM Z stage with brake ( 4 inches of travel)2 BMS60-A-D25-E2000H motors with rotary add-ons for the stages1 Z axis BMS60-A-D25-E1000H for focus1 rotary BMS60-A-D25-E1000H motor for the spindle with built in brakeOptical plate and base with live video camera and built-in LED illuminationFixture base plate with slotsDIN rail for additional IO Dual illumination system for side illumination and illumination for the live video (needs 24VDC power supply)Swappable rotary spindle (replacable by an off-the-shelf 100K to 200K RPM spindleMade to be used as a micro-milling device which can machine very small parts on the order of 100 microns4 Axis Precision Motion Controlled Milling Machine w/Measurement Software


Custom Systems UV Excimer Laser IntegrationCustom Systems Retrofitted Into Existing Automation Lines

Integration of custom laser solutions into existing manufacturing systems. Clean room class 1000 Microprocessor System Controller with Advanced Burst Mode Power Leveling and Smart Flow SystemAdvanced Gas Cabinet with Tank Minder FeatureUltra-Stable Class I Enclosure

Custom Drilling System for Medical Applications


The verification of each calibration constant was performed by measuring a known feature size using the NIST traceable calibration slide as displayed in the squares in the live video display below:

The features size according to the documentation that came with the slide is 50 microns. The vertical (50.9) and horizontal (50.3) measurements indicate that there is up to a one (1) micron error in the 40X objective measurement. Each of the four (4) cameras corresponds to a different microscope objective. All must be calibrated.Software Engineering - Offline NIST Traceable Measurement for Job ShopThe final phase of the calibration and measurement portion of the purchase order was to password protect the calibration constant.

Each of the 4 calibration constants corresponds to 20X, 40X, 160X and 800X.

This calibration constant is used for the measurement for both in-situ and offline metrology.


The measurement tools available are the following:

Two (2) X moveable and non-destructive horizontal overlay calipers which can be added and removed from the screen

Two (2) Y moveable and non-destructive vertical overlay calipers which can be added and removed from the screen

Four (4) Y circular calipers which can be sized to measure the complete diameter of a hole and provide a template from which one can evaluation the Ovality (roundness) of the hole

A tape measure capability which allows measurement of a feature that does not fit within the live video field of view & motion integrated

Software Engineering - NIST Traceable Measurement for Job Shop


RPI Laser Deposition System using 193nm Excimer

This laser system design contains motion systems in order to move the material to be applied and the other to move the substrate.One X / Y stepper motor controller to move the material which will be applied to the work surface.The other X / Y / Z precision servo motor controller to move the actual work surface.


RPI Laser Deposition System using 193nm Excimer


RPI Laser Deposition System using 193nm ExcimerThe application running on the left of the screen controls the precision substrate motion.The smaller application on the right controls the material which will be applied to the work surface.Communication between the two applications motion occurs via the primary motion controllers U Axis which was unused. I created an state machine using position values as a communication method between each application. Because there was no U Axis, I disabled all fault conditions, effectively allowing the apps to communicate via known programmable position values. This was a creative solution to a problem not known until installation.


In-Situ Measurement Implementation for Catheter Drilling

This view provides 100% measurement while actually machining the part. If the part is left in-situ, we can measure the actual exit dimensions non-destructively.

To the right is a part that had just been drilled and what the measurement of the exit hole would be.

This picture is be one of the deliverables as verification of the drilling process.The next phase of the work that TeoSys took upon itself to perform is the transition from 100% offline measurement to 100% on-line or in-situ , measurement. All measurement deliverables will be collected during the drilling process itself. See below:


In-Situ Machine Vision Implementation for Part OrientationCustom Human Machine Interface to find out of centration features of multiple fiducials (points of reference) on the plate of parts and The software will autogenerate code to rotate the plate to achieve centration before performing micro-machining.

The application displays the offset from the expected position which indicates how much the plate is rotated at the fiducial location.

The box on the lower right displays the actual motion code (scripting language & IDE invented by Dana Church).


Micro Operator: Custom Real Time Machine Vision System written in C++Micro Inspector: Post-process Measurement and Inspection Tool (below)Software Engineering Machine Vision ApplicationsAligns part during process and compensates for rotation errorHalts process if pre-programmed conditions are not met thereby reducing improperly processed partsNotifies operator of processing statusFull video microscope capabilityProvides saving and loading of previously processed imagesAllows images to be non-destructively overlaid with user supplied text such as title, date, etc.Fully integrated with motion system for complete process inspectionMicro View C++Simple video microscope capability


Software Engineering Proprietary ProductsMicroMMI: Real Time Machine Vision SystemMultiple image processing algorithms (source code) available via proprietary vision system language (Based on RS-274)Image processing source automatically generated via MicroCaliper program and may be copied into MicroMMI editorFully integrated with motion system for pre/post/in-processing inspection, measurement and quality controlProvides full in-process laser and system controlProvides an integrated development environment for operator to single step, edit, and debug motion control programs written in the vision system language

Allows operator to make measurements of features within the live video image once the software has been calibrated to the optics and motion system

Software Engineering Machine Vision Applications


Software Engineering Machine Vision ApplicationsThe MicroMMI application is a Graphical User Interface (GUI) which allows a user to program a micromachining system using a superset of RS 274, G-Code, motion control programming commands and view a live video feed set up to display aspects of the micromachining process. Proprietary machine vision commands have been added to the motion control programming commands to allow the user to make motion-based decisions from the output of real time image processing and measurement.

ROI ADDROI DELETEROI HIDEFIND EDGEFIND BLOBTHRESH AUTOTHRESH BILEVELROI TRAINFIND PATTERNIMAGE LOADIMAGE SAVEIMAGE REDRAWBRIGHTENSHARPENDILATE ERODEOVERLAY TYPEOVERLAY COLORDRAWINGGRAPHICS

The Machine Vision Functions Available are the following:


In order to aid the engineers during experimentation, TeoSys has provided an image and machine vision prototyping application, which can be used to apply the various machine vision algorithms without writing a single line of PRG code. This tuning program allows the user to experiment with all of the machine vision commands before actually using them in a PRG program. Due to the many variables involved when using any kind of image processing, this user interface was designed to provide a nondestructive method of testing which image processing and measurement functions should be used for a particular video stream. All of the functions that are available in this prototyping interface are available via PRG programming commands to the MicroOperator application so that they may be used in real-time in a motion control program.

The machine vision prototyping application will automatically generate the machine vision PRG programming syntax for each of the commands that the user applies via the user interface. This PRG code can then be copied and pasted into any PRG program that is capable of running with MicroMMI. Machine Vision SystemPrototyping Software


1. Original Fiducial Image Used to Train Fiducial Pattern

2. Image of Defocused and Moved Fiducial The geometrical Search tool is a very good tool to use when searching for a pattern that moves around the master image, changes intensity, suffers from blurring or defocusing, and for patterns that reverse their contrast. Image number 1 was used to train a fiducial pattern. The ROI was drawn around the fiducial so that the ROI bounding box just enclosed the fiducial fully. After the training was complete, a new image was loaded that was a picture of the same fiducial but its location within the master image had changed and it was severely defocused. The geometrical search algorithm had no problem finding the fiducial in picture number 2.The Search tool can be used to find a trained pattern within the master image (field of view) and make a decision to continue based on the presence or absence of the fiducial or on the fiducials location. All patterns must have geometrical characteristics that can be seen such as the fiducial above. The pattern must be unique and different from the rest of the image. It is best to have images that respond well to the Bi-Level threshold. If the master image (or field of view) responds well to the Bi-Level, then most characteristics should be able to be found.


Micro-Hole Drilling In CeramicIn Glass3.6um hole deep bored In GlassDeep Hole Boring9um spout entrance and 30um spout exit) Example of Sub-surface shaping.

(30um deep bore , Hole Drilling in 1MM Soda Lime Glass

Close up view of intra-glass nozzle restrictionApplications Deep Hole Drilling in 1MM Thick Glass Slide


3.6um hole deep bored In GlassDeep Hole Boring50um Exit holes in thin polyurethaneCheaper and better capability than using an excimer which has a higher maintenance cost.

The software seen to the left is an example of how we measure our parts.

All objective on the 4 piece turret are calibrated to a NIST traceable slide so that we can guarantee actual measurement and tolerance specifications.Applications 532nm Polyurethane hole drilling



27um Kerf Lines on Aluminum Cross PatternLaser Ablation

25um Channel in PlasticTop Hat Shape Strict Bottom ProfileExcimer laser channel drilling for microfluidics (left) as well as thin film ablation (right).

Channel drilling for tube bending applications where the entire wall is removed (bottom right).27um Lines on Aluminum Using Back Lighting as illumination


Applications Channel Drilling Parameter Definition

Key Tube Cut Design Parameters Cut width (kerf) Spacing between groups Spacing within a group Number of groups Rotation between each line in a group

Varying of these parameters will result in successful flexibility for the different tube diameters and flex requirements



Applications Micro Hole Drilling

Laser Hole Drilling(Micro Hole Array)Micro-Hole Drilling In CeramicIn Glass

3.6um hole deep bored In GlassDeep Hole Boring

High Speed Micro Hole Drilling in Stainless Steel ( 0.001)

Hole Drilling in Silicon (10um and 50um)


Applications Micro-Marking / Inscription

100 um Inscription on Diamond

High Speed Inscriptions in Polyimide (Text, Logos and 2-D barcode)2-D Barcodes on Metal1mm Square Bounding BoxExcimer marking using line widths down to 5 microns.

Small feature micro marking on transparent media.

75 Micron tall characters with 26 micron line thickness (fully adjustable via ICVA) internal to the excimer laser.


Single pulse implementation of a 2D Data Matrix barcode

Barcode is readable via a video microscope display screen using a Data Matrix 2D barcode scanner device.

TeoSys Engineering LLC Capabilities & Products Capabilities Part Marking for Identification

Data Matrix 2-D Barcode on Stent LegPrecision STENT Marking


Dana Lee Church - Engineering Capabilities r14

Engineering

Transcript of Dana Lee Church - Engineering Capabilities r14