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The Electric Flame-Off Assembly

Spring-loaded v-groove Decoupled adjustment Minimizes slop. Self-locking spring Minimizes # of parts Self-locking. The Electric Flame-Off Assembly Team 12: Eric Busillo, Greg DuBois, Jesse Krisher, & Curtis Pierce Sponsors: Mike Schmidt-Lange, Mike Gauger, & John Molnar

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The Electric Flame-Off Assembly

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  1. Spring-loaded v-groove • Decoupled adjustment • Minimizes slop • Self-locking spring • Minimizes # of parts • Self-locking The Electric Flame-Off Assembly Team 12: Eric Busillo, Greg DuBois, Jesse Krisher, & Curtis Pierce Sponsors: Mike Schmidt-Lange, Mike Gauger, & John Molnar Advisor: Dr. Michael Keefe Testing & Validation Project Objective Concept Development FEA TESTING: To design and develop a successful prototype of an electric flame-off assembly for the next generation of Kulicke & Soffa wire bonding machines. Current EFO Assembly Stress Distribution: Deflection: Guidance Locking Coupled adjustments cause multiple attempts to precisely locate electrode No preload results in slop during adjustment Wire Bonding • What is it? • Bonds semiconductor chips to circuit boards • Chips used in cell phones, computers, video game consoles, etc. • Uses a “ball bonding” process, which is used in 90% of wire bonding applications SOLUTION SOLUTION Adjustment 1st Mode resonance: 1.01 kHz -Resonance Test: Deflection of 0.0004 in. at 25 G -Wand Deflection: Set screw leads to multiple operations per adjustment CONCEPT TESTING: • Self-locking Concept: • Does the screw-spring system self lock? • 25g load • Frequencies of 50-300 Hz • No screw loosening occurred SOLUTION PROTOTYPE TESTING: • Decoupled Adjustments & Slop During Adjustment: • Optical Comparator • Test for deviation from linear • adjustment • Max deviation = 0.005 in. • Wand Deflection: • Shaker & High-speed Camera • Test for unwanted wand vibration • Max deflection ~0.002 in. • Frequency: • Scanning Laser Vibrometer • Test for resonant frequency • Resonant Freq. = 594 Hz Top Wants • Decoupled Adjustments • Easy Access to Adjusting Hardware • Low Cost • Precision • Similar Means of Adjustment • Ease of Assembly • Light Weight • Adjustable screw • Infinitely adjustable • Consistent means of adjustment (Pictures from vibrometer testing) Final Design Top Metrics Target Values: Project Transition • # of Coupled Adjustments………………….0 • Deviation from Linear Adjustment.....<0.003 in. • Cost………………….…………………….<$112 • # of Operations for Adjustment……..……..3 • Clearance for Adjustment.…..…………...>6 in. • Slop During Adjustment.………………<0.005 in. • Wand Deflection..………………………<0.005 in. • Min. Adjustment Distance ………….…<0.001 in. • Weight..…………….………………...…<0.12 lbs • Resonant Frequency…………………...>600 Hz • Optimization of Design: • Decrease weight • Increase resonant frequency • Decrease friction between plate and springs • Design assembly guide and apparatus • Stress & fatigue testing • Tolerance analysis to address deviation Plastic divider EFO Assembly (~3:1 scale)

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