Video – Robotic IC Programming

Today’s printed circuit boards often include embedded software or firmware as part of the design. The code is stored in microcontrollers or flash memory chips. If you outsource printed circuit board assembly to a contract manufacturer, you need to consider how these ICs will be programmed.

In-circuit manual programming

Many devices can be programmed in-circuit. This is common in prototype development. It’s easy to iterate and trouble-shoot the software in tandem with the hardware changes. But in-circuit programming is too time-consuming for anything but the first few prototypes.

Universal IC programmer for manual programming

We can use a universal IC programmer to speed things up a bit. Once an IC is placed in the programmer, it takes only a few seconds to transfer the data and check it. But it’s a manual process to pick each IC, place it in the socket, start the program, and unload when finished. An experienced production worker can program about 100 parts per hour. That’s suitable for pre-production runs and some low-volume production jobs.

But as with any tedious manual process… when fatigue sets in, it’s easy to make mistakes, such as missing the indicator that a device failed to be programmed. That leads to quality problems later.
It also adds a lot of labor cost to each part, and takes skilled mfg workers away from higher-value activities such as assembly, inspection, or testing.

Robotic IC programming

So higher-end, high-mix contract manufacturers may invest in robotic handling systems to automate IC programming. This is the robotic programming system used at Z-AXIS. The operator loads a reel of parts and starts the system. The “SuperBot” automatically begins loading and programming ICs. It tests each one to verify that it’s programmed, and sets aside any that need to be re-done. It can run that same 8-bit device we showed earlier, at about 2,100 parts per hour. That’s twenty times faster, and with almost no labor cost.

The equipment investment for robotic IC programming runs from $70,000 to more than $400,000 for systems that can handle the small SOT-23 packages commonly used for microcontrollers.The payoff is higher throughput, lower costs, and error-free programming.

Buying pre-programmed ICs

Another option is to buy pre-programmed ICs from your parts distributor or a programming service. You send your firmware file to the IC distributor, and request a first article for testing. The lead time for production parts is typically 3-4 weeks after first article approval. This means if you have a new product — or even just a firmware update — you’ll be waiting several weeks for programmed ICs. In contrast, with automated IC programming in-house, your contract manufacturer can be running production parts with your updated firmware the same day you send us the file.

We have found automated programming costs about 50% less than manual programming and 30% less than buying pre-programmed ICs, in the low- to mid-volume quantities our customers need.

Combining manual processes for prototypes with automated processes for production

So at Z-AXIS we combine in-circuit and manual programming for prototypes and pre-production runs, with automated robotic programming for production. It’s one more way we deliver lower costs, higher throughput and highest quality for our customers.

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