Ensuring Reliable Microchip Feeding with Machine Vision

The Challenge

As semiconductor components continue to shrink, ensuring their accurate handling becomes increasingly complex. The customer required a solution that could reliably detect the position and orientation of microchips with edge lengths smaller than one millimeter. Even minor deviations during robotic handling can damage delicate microchips, resulting in costly material losses. Inaccurate positioning or rotation can further affect downstream processes and reduce efficiency. Because of this, the client needed a vision system to remain perfectly synchronized with the handling equipment and guarantee consistent positioning data throughout operation.

The Solution

senswork developed a customized VisionUnit sensor specifically designed for this demanding application. The camera module accurately detects both the position and rotational alignment of microchips, even when handling components with dimensions below one millimeter. The captured data is transmitted directly to the system controller, enabling precise and reliable automated handling.

A key element of the solution is an integrated calibration algorithm that continuously ensures the camera system and handling equipment operate within the same coordinate system. This automatic calibration eliminates alignment discrepancies and guarantees repeatable measurement results without manual intervention.

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Image evaluation is performed using senswork’s VisionCommander® software, which provides reliable and efficient processing tailored to the application requirements. The modular design of the VisionUnit allows seamless integration into the customer’s existing automation environment while maintaining the flexibility needed for future adaptations.

Results

The implemented solution delivers dependable verification of microchip positioning and orientation, ensuring smooth operation of the automated feeding process. Even extremely small chips can be inspected with high accuracy, providing the reliability required in semiconductor manufacturing environments. By combining precise detection capabilities with automated calibration and a modular architecture, senswork created a future-proof vision solution that supports consistent production quality and predictable system performance.

Want to learn more about using machine vision for semiconductor manufacturing? Read more here.