月: 2024年1月

What Is Gypsum Casting?

Gypsum casting, also known as plaster mold casting, is a method used in semiconductor manufacturing for creating molds using gypsum. This technique is essential for producing products with complex shapes and high precision in small batches.

Unlike traditional mold-based casting, gypsum casting involves pouring molten metals directly into gypsum molds, allowing for greater design freedom and flexibility. Commonly used metals include aluminum, magnesium, and zinc, with aluminum being the most popular choice.

The process offers benefits such as shortened production periods, cost reduction, and the ability to easily accommodate design changes. Gypsum casting is particularly effective for vacuum casting, making it suitable for producing intricate shapes and achieving smooth surface roughness.

Uses of Gypsum Casting

Gypsum casting is widely used in various industries for prototyping and small-batch production. Its precision is comparable to die-casting, making it ideal for creating automotive components, electrical and mechanical parts, medical devices, and crafts.

Principles of Gypsum Casting

The process begins with creating a master model from 3D data, followed by mold creation using silicone. Molten aluminum is poured into the gypsum mold, and the final product undergoes finishing work like burr removal. This method is suitable for producing detailed items such as miniature car models.

Structure of Gypsum Casting

Gypsum used in casting typically contains additives to improve various properties. Its composition is generally 70-80% gypsum and 20-30% additives. Gypsum casting is suitable for non-ferrous metals due to its maximum temperature limit of around 1,200°C.

How to Choose Gypsum Casting

Gypsum casting is ideal for creating precise and aesthetically pleasing prototypes and small-batch products. It is cost-effective for molding intricate shapes and allows for product improvements without mold-related expenses. This method is suitable for quantities up to a few hundred, beyond which die-casting may be more favorable.

Heat treatment can be applied to achieve mechanical properties equivalent to die-cast products, considering the gradual cooling of molten metal in gypsum casting.

Other Information on Gypsum Casting

The process involves creating a master model based on CAD or CAM data, followed by mold making and molten metal pouring. After the gypsum mold solidifies, the metal is poured to create the casting, which is then demolded.

What Is a Filament?

A filament is a long, continuous fiber often used in the textile industry. It can be made from cellulose or synthetic materials, producing indefinitely long threads. In contrast to short-fiber materials like cotton (staple), a filament refers to a single, unbroken fiber.

In chemical fiber production, filaments are created through spinning, with fiber thickness adjusted for different applications. These filaments are then used in textile manufacturing, either directly or as part of filament yarns.

Silk threads, for example, can be monofilament (single filament) or multifilament (multiple thin fibers), each offering different characteristics.

Uses of Filament

Filaments are versatile, finding applications in clothing, sports equipment, industrial materials, and high-density fabrics. They are used in sports nets, racket strings, fishing lines, bicycle and golf club shafts, outdoor furniture, and tents.

In industry, filaments are used in products like nets, ropes, filters, and electrical wires. Carbon fibers, a type of filament, are used in aerospace and automotive applications due to their strength and lightness.

High-density fabrics made from filament threads are used in products like umbrellas and roller screens, offering low light and water permeability.

Properties of Filament

Filament threads have a smooth surface, producing stable and smooth fabrics. They are often treated to reduce glossiness, providing a luxurious appearance. Filament yarns create finer tightly woven fabrics suitable for various applications, especially where strength is needed.

Types of Filaments

Monofilament consists of a single filament and is usually made from synthetic fibers like polypropylene, polyester, or nylon. Multifilament comprises multiple long fibers and can include microfibers.

How to Choose Filament

1. Monofilament

Monofilament is strong and suitable for applications requiring firmness, such as tennis racket strings and fishing lines. It can be dyed during production and is often used in transparent fabrics. However, it can cause discomfort if too thick.

2. Multifilament

Multifilament creates soft, supple fabrics, less prone to wrinkling, and can offer UV protection. They are used in wind-resistant jackets and various other applications but have lower strength than monofilaments and may attract surface dust.

What Is Dicing?

Dicing is a precision process used in semiconductor manufacturing, typically following the photolithography stage. It involves cutting individual chips from a wafer, each containing its own set of operations and processes. This method is characterized by high precision cutting techniques and is crucial in the production of semiconductor devices.

A wafer can contain tens of thousands of chips, each separated by scribe lines. Dicing is performed along these lines using specialized equipment, such as a dicer or a laser dicer. The process requires high precision, typically along scribe lines of about 100μm or less. Common dicing methods include mechanical dicing with a thin circular blade (dicing saw) and laser dicing using thermal stress.

While primarily used for semiconductor wafers, dicing is also applicable to other electronic components like MEMS, ceramics, and glass, often provided as a contracted service due to the precision required.

Uses of Dicing

Dicing is essential in semiconductor manufacturing to separate individual chips from wafers. It is applicable to various wafer materials with different mechanical characteristics, including silicon, silicon carbide, and gallium nitride.

The process is also used in precision electronic components like MEMS, LEDs, and sensors. In broader applications, dicing is employed in industries such as packaging, automotive components manufacturing, and textiles for cutting materials into specific shapes and sizes.

Principles of Dicing

Dicing semiconductor wafers requires high processing precision, focusing on cut line accuracy and chipping width. Dicing devices include dicers and laser dicers, each offering distinct advantages in precision and process.

1. Dicer

Dicers use an ultra-thin circular blade to cut through the wafer, often employing diamond-tipped blades for precision. They are known for their high-speed cutting capability and may use pure water during the process.

2. Laser Dicer

Laser dicers utilize laser technology for cutting, including ablation processing and the Stealth Dicing™ process. This method is advantageous for its dry process and reduced environmental impact.

How to Choose Dicing

Companies may either conduct dicing in-house or outsource it. In-house dicing requires selecting suitable equipment based on processing precision, quality, speed, and cost. For outsourcing, considerations include compatibility with the material, processing method, quality control, delivery time, and pricing.

What Is CMP?

CMP, chemical mechanical polishing, is a technology used for precision polishing of semiconductor wafers in large scale integration (LSI) and micro electro-mechanical systems (MEMS).

This process, requiring nanometer-level precision, smoothens surfaces to an extremely fine degree, achieving angstrom-level surface smoothness. It combines mechanical and chemical processes by applying a chemical abrasive on a polishing pad to polish the substrate surface.

Advanced technology and expertise are essential in CMP equipment, polishing pads, and abrasives to achieve such precision.

Uses of CMP

CMP is critical in semiconductor device manufacturing, polishing substrates like silicon wafers. It is also used in MEMS substrates, glass substrates for displays, HDDs, and solar cell production. CMP’s precision makes it vital for producing high-performance semiconductor chips and displays.

Principles of CMP

CMP involves three key elements: polishing abrasives, chemical agents, and a polishing pad.

1. Polishing Abrasives

These are in liquid or slurry form, containing abrasive particles. The abrasive type varies depending on the substrate material and desired finish.

2. Chemical Agents

Chemical agents assist abrasives in smoothing the surface. They include oxidants, reducers, additives, and solvents like water or alcohol.

3. Polishing Pad

The pad is mounted on a rotating table larger than the substrate. During polishing, the substrate is pressed against the pad while both rotate in opposite directions.

After polishing, the substrate undergoes cleaning and inspection for surface flatness and roughness.

How to Choose CMP

Choosing CMP involves either building an in-house line or outsourcing to a specialized company.

1. In-House Line Construction

In-house CMP requires selecting suitable equipment, designing processes, maintaining systems, and training engineers.

2. Outsourcing to Specialized Companies

Outsourcing involves selecting a company that can provide comprehensive CMP services, including equipment and process development.

What Is PE Film?

PE film, made from polyethylene, is a type of crystalline thermoplastic resin widely used in various applications.

Developed around 1950 using the Ziegler-Natta catalyst, polyethylene quickly became a popular plastic material. It comes in several types, such as linear low-density (LLDPE), very low-density (VLDPE), low-density (LDPE), high-density (HDPE), and ultra-high-molecular-weight (UHMW-PE) polyethylene.

Known for its ease of processing and cost-effectiveness, polyethylene is used extensively where high heat resistance and mechanical strength are required, especially in its ultra-high molecular weight form.

Uses of PE Film

PE film is used in various sectors, including packaging for food and industrial products. LLDPE and LDPE are favored for their transparency in packaging materials. HDPE is used in construction materials like pipes, while UHMW-PE finds applications in medical equipment and bulletproof vests.

In Japan, which has a significant production capacity for polyethylene, PE film is also used for waterproofing in construction, wire coatings, and submarine cables.

Properties of PE Film

PE film is chemically resistant, insulating, oil-resistant, and waterproof. It is affordable and easy to process, but it is vulnerable to heat and fire. It is nearly non-absorbent, highly waterproof, and floats due to its low density. PE film also has high electrical insulation properties.

Types of PE Film

PE film is classified into LDPE and HDPE based on density. LDPE is softer with good transparency but lower mechanical strength, while HDPE is stronger and more heat-resistant but less transparent.

Other forms include VLDPE, LLDPE, and UHMW-PE, each with unique properties such as very low density or ultra-high molecular weight.

Structure of PE Film

Polyethylene is a simple polymer consisting of repeated methylene units. Its structure varies based on polymerization methods and molecular weight, affecting its mechanical properties and density. Innovations like the metallocene catalyst have allowed more precise control over polyethylene’s molecular weight.

How to Choose PE Film

When selecting PE film, consider its application. Options include stretch film for packaging and protective films for various surfaces. Specific choices should be based on the film’s intended industrial or packaging use, such as stretch hood film, adhesive film, heat shrink film, or films designed for packaging specific products like oils or toothpaste.

What Is EtherCAT?

EtherCAT (Ethernet for Control Automation Technology) is an industrial network standard compatible with Ethernet, designed for high-speed, efficient, and precise synchronization in field networks.

It connects various elements like computers, controllers, and drive devices (sensors, measuring instruments, motors) in industrial networks. EtherCAT is distinct from LAN used in information systems and is recognized for its high-speed communication capabilities.

The EtherCAT Technology Group (ETG) defines its functional requirements and certifications, with about 2,400 member companies worldwide.

Uses of EtherCAT

EtherCAT is widely used in industrial automation, efficiently connecting drive devices, controllers, and computers. It is applicable in various industries including robotics, welding, cranes, measurement devices, and more.

Principles of EtherCAT

EtherCAT allows flexible connection forms like line, tree, star, and daisy-chain. In a daisy-chain setup, information transfer follows a bucket relay fashion, where each slave processes relevant instructions and forwards the frame.

Configuration of EtherCAT

The network consists of a master control device and slaves (input/output devices). Connections can vary, and devices are typically connected using RJ45 twisted-pair cables. EtherCAT frames are inserted into Ethernet frames for transmission.

Types of EtherCAT

EtherCAT has evolved to include EtherCAT P, EtherCAT Automation Protocol (EAP), and Safety over EtherCAT (FSoE).

1. EtherCAT P

EtherCAT P integrates power supply with EtherCAT communication, reducing the need for additional cabling and supporting device miniaturization.

2. EtherCAT Automation Protocol (EAP)

EAP allows higher-level operating devices on a generic LAN to control EtherCAT-connected devices.

3. Safety over EtherCAT (FSoE)

FSoE focuses on safety in factory control through EtherCAT communication.

Other Information on EtherCAT

1. Difference from Ethernet

EtherCAT uses Ethernet frames but bypasses TCP/IP protocol processing for higher speed. It requires hardware capable of withstanding industrial environments and has a connection limit of 65,535 devices.

2. Performance

EtherCAT is one of the fastest industrial Ethernet technologies, with low CPU load and high-speed communication capabilities.

3. EtherCAT Slave and Master

Diverse EtherCAT slaves are available, and custom development is possible. Any PC with an RJ45 Ethernet port can serve as an EtherCAT master, simplifying the implementation.

What Is Concrete Testing?

Concrete testing is the process of evaluating concrete to ensure it meets the required performance and quality standards for construction projects.

As a critical material in building, road, bridge, and various other constructions, concrete is made by mixing cement with sand, gravel, water, and additives. Testing is vital to confirm that the concrete has the necessary strength and durability for these applications.

Uses of Concrete Testing

Concrete testing serves multiple purposes, including assessing concrete performance, managing quality, and evaluating workability. In many countries, specific tests are legally mandated for construction-grade concrete. These tests are often based on national standards.

Performance tests assess properties like compressive strength, flexural strength, and durability, using solid concrete specimens. Quality tests analyze the concrete’s composition to ensure it meets established guidelines and standards.

Principles of Concrete Testing

Key concrete tests include:

1. Compressive Strength Test

This test measures the concrete’s ability to withstand compressive forces. The Amstler method applies pressure to a cylindrical concrete specimen to evaluate its strength.

2. Durability Tests

These tests assess the concrete’s resistance to environmental factors, including freeze-thaw cycles, salt permeability, and potential alkali-silica reactivity, which can cause expansion and degradation over time.

3. Tensile Strength Test

This test evaluates the tensile strength of concrete, while flexural strength tests measure its bending resistance. Permeability tests assess the concrete’s ability to resist water penetration.

Types of Concrete Testing

Concrete testing can be divided into acceptance inspections of fresh concrete at construction sites and strength/durability tests on hardened samples in laboratories.

1. Acceptance Inspection

This inspection assesses freshly delivered concrete for properties like slump, air content, and temperature. It is time-sensitive, as the characteristics of fresh concrete change rapidly.

2. Strength and Durability Tests

These tests are conducted to confirm the concrete’s composition and strength. Factors like cement type, aggregates, and additives can significantly impact concrete’s strength and durability.

How to Choose Concrete Testing

Choosing the right concrete tests involves identifying the specific test items and methods needed. When outsourcing testing, it is crucial to ensure that the chosen service provider can conduct the necessary tests effectively and accurately.

What Is a BNC Cable?

A BNC cable is a type of coaxial cable commonly used in high-frequency analog signal measuring devices, such as oscilloscopes.

BNC cables come in two impedance varieties: 50Ω, typically used for power transmission in radios, and 75Ω, used for transmitting video and audio signals in devices like TV receivers. The cable consists of a coaxial cable fitted with a BNC connector, known for its quick connect-and-disconnect capability and locking mechanism that secures the connection without the need for screwing.

The term, BNC, is believed to be derived from Bayonet Neill Concelman, combining the bayonet locking mechanism with the name of the connector’s inventor, Neill Concelman. Other theories suggest it stands for Bayonet Connector or British National Connector.

Uses of BNC Cable

BNC cables are used in various fields, including telecommunications, measurement, computing, and audiovisual equipment. In telecommunications, they are used for high-frequency signal transmission in equipment like FA controllers. In the audiovisual domain, 50Ω cables serve as LAN cables, while 75Ω cables are used for video and audio connections.

Due to their compact size, affordability, and excellent frequency characteristics, BNC cables are also used as an alternative to RCA connectors for transmitting electrical signals.

Principles of BNC Cable

BNC cables feature a bayonet lock mechanism for easy engagement. This mechanism allows for a secure connection with a simple twist and is designed to prevent accidental detachment even when the cable is pulled, due to its spring-based locking system.

Structure of BNC Cable

The cable combines a BNC connector with a coaxial cable and may include branched lead wires at the tip. Various types are available, including those with male connectors on both ends, branching with a clip for measurements, and robustly soldered lead wires.

These cables often use UL1015-AWG18 wires, and lead-free solder is utilized for connections, making them environmentally friendly. Before shipment, BNC cables undergo several quality assurance tests, including insulation and withstand voltage tests.

How to Choose a BNC Cable

When selecting a BNC cable, consider the application: 50Ω cables for oscilloscopes and precision measurements, and 75Ω cables for video and audio transmission, such as in household TV setups. For applications requiring high power transmission or precision measurement, specialized commercial coaxial cables are recommended.

BNC cables are also used for audio equipment connections, analog surveillance camera transmissions, and in industrial applications with surge protectors and arresters.

What Is a Shrink Labeler?

A shrink labeler is a machine that applies heat to shrinkable film labels, wrapping them tightly around products such as PET bottles.

Products are fitted with oversized labels and then passed through the shrink labeler. Inside, heat is applied, causing the label to shrink and conform to the product’s shape. This process results in a tightly fitted shrink label.

An example is a polypropylene (PP) salad dressing bottle with a polystyrene (PS) shrink label covering the bottle and cap. The label includes perforations for easy cap opening and can be peeled off for recycling or disposal.

Shrink labels are versatile, fitting containers of any shape, including those with caps or lids. They are widely used in beverages, food products, daily necessities, and pharmaceuticals.

Similar to a shrink labeler, the L-type shrink system also uses heat-sensitive film to fully wrap products.

Uses of Shrink Labeler

Shrink labelers are primarily used for applying labels to beverage containers, cosmetic products, and condiments. They are suitable for labeling PET bottles, aluminum cans, cosmetic containers, and food condiment packaging. The labels can also serve as tamper-evident seals on cup-shaped confectionery items.

Principles of Shrink Labeler

To apply a shrink label, a heat-shrink film is cut into a cylindrical shape and fitted over the product. The shrink labeler then applies heat, using either hot air or steam, causing the label to shrink and tightly adhere to the container.

The label’s appearance is crucial for product image, and manufacturers have developed various methods for attaching and heating labels. To prevent product damage, parameters like heating temperature and duration are adjustable.

Films used include PS, PET, and environmentally friendly options like biodegradable and plant-based films.

How to Choose a Shrink Labeler

When choosing a shrink labeler, consider its shape, size, throughput, initial and running costs, label finish quality, and product handling versatility. The label’s appearance impacts the product’s image, so consistent, high-quality labeling is vital.

For diverse product ranges, select a shrink labeler with broad compatibility, including irregular shapes and eco-friendly films. Some manufacturers offer free sample creation, allowing for quality evaluation before purchase.

What Is a Production Scheduler?

A production scheduler is a software-based information system that aids in creating production plans and schedules within a factory.

It translates production plans into specific timelines, detailing start and completion dates for each product, task assignments, worker allocation, and detailed machine operation times. In factories with multiple processes and various manufacturing facilities, production scheduling considers orders, quantities, and delivery deadlines to ensure efficient use of resources while meeting customer demands.

Effective production scheduling is crucial for profit generation, requiring efficient utilization of personnel, facilities, and materials, and adherence to delivery deadlines. The production scheduler supports schedule creation and enables real-time adjustments based on feedback from the manufacturing site, thus broadening the capability beyond those intimately familiar with the processes.

Uses of Production Scheduler

As a critical tool in production management, the production scheduler coordinates with upstream systems to manage production plans, optimize resources, handle delivery deadlines, and manage inventory.

1. Management of Production Schedule

This function compiles production processes into a timetable, optimizing activities based on operating hours, worker assignments, and machine conditions.

2. Optimization of Resources

It aids in maximizing personnel, facility, and material use to boost productivity and operating rates.

3. Delivery Deadline Management

Manages individual product deadlines, allowing schedule adjustments and tracking progress to predict and address delays.

4. Inventory Management

Supports material management for production, creating plans to maintain appropriate inventory levels based on demand forecasts.

Principles of Production Scheduler

The scheduler operates in cycles of demand forecasting, production planning, setting up part structures and resources, creating and updating schedules. It involves predicting demand, planning production quantities and periods, understanding product structures, and configuring necessary resources.

Post demand forecasting and planning, schedules are created considering start times, procedures, assignments, machine times, quantities, priorities, and delivery dates. Constant adjustments and updates to the schedule based on actual conditions are crucial for efficient production management.

How to Choose a Production Scheduler

When selecting a scheduler, consider its ease of use in planning and schedule creation, flexibility in settings, and adaptability to changes. Real-time understanding of on-site conditions and effective communication of schedule changes through interfaces and integration with other management systems are also important factors.