[Gta04-owner] [Tinkerphones] Status of GTA04A5 production +++ has started +++ video available

Tue Sep 27 15:16:27 CEST 2016

Hello, 

Did you see this paper
http://www.nordson.com/-/media/Files/Nordson/dage/Products/X-ray-Technical-Papers-and-Articles/Semiconductor-Inspection-and-Assembly/POP-paper-SMTA-2009-final.pdf
? 

They are giving other possible soldering failure causes for POP
packages. I hope this will help... 

Regards 

Thierry GRAUSS 

On 26/09/2016 18:51, H. Nikolaus Schaller wrote:

> Hi all, 
> today we tried to solder the other side and get working GTA04A5 board, 
> but sadly we failed. 
> 
> The boards look optically fine 
> 
> but DM3730 has short circuits in the middle under the chip :( 
> 
> The production company has recently bought their own X-Ray machine so that we can immediately see the problem. 
> 
> But we don't know the reason. 
> 
> Well, we know this problem exists with all OMAP3 and DM3730 chips and it 
> is warpage during the soldering process. Texas Instruments has published 
> some documents and application notes about this problem, but basically they 
> have no clear solution. Just a recommendation to experiment. 
> 
> We already did fight a while with this during the assembly of GTA04A3 and 
> GTA04A4 boards,  but finally using a vapor phase soldering machine its was solved. 
> 
> This time we also use a vapor phase machine right from the beginning. The 
> same that was used to produce some of the 600MHz OpenPandora and all 1GHz 
> OpenPandora devices. Which were successfully produced after some startup 
> issues. 
> 
> We simply do not see any obvious reason why it fails so badly this time. 
> 
> This needs some time to analyze and make more experiments (but ideally 
> not by wasting expensive and scarce chips and PCBs). 
> 
> So I have to regret that we can't ship the first GTA04A5 boards this week 
> as planned. 
> 
> I will keep you updated as soon as we find out something. 
> 
> BR, 
> Nikolaus Schaller 
> 
> Am 25.09.2016 um 18:02 schrieb Neil Jerram <neil at ossau.homelinux.net>:
> 
> Thanks for creating that video; previously I had no direct idea of what this kind of production is like.  It's very illuminating to see it.
> 
> Neil
> 
> On 24/09/16 08:38, H. Nikolaus Schaller wrote:
> Am 22.09.2016 um 17:31 schrieb H. Nikolaus Schaller <hns at goldelico.com>:
> 
> Hi,
> we are coming closer...
> 
> I had a short meeting to discuss placement of some components today.
> For example the position of the two LEDs is not easy to determine because
> they are tilted a little.
> 
> But the whole GTA04 design is more complex than they thought, so that
> they had much more work than planned to program the Siplace system.
> This was intersting to see.
> 
> Basically they have a CAD system where they read in the Gerber files
> and overlay Pick&Place positions and component packages. Components
> can be shifted and rotated manually if needed. This is automatically
> replicated for a multiple panel.
> 
> I have already seen the boxes with all components. Those are tempered
> tonight and tomorrow they do the setup. Depending on how long it needs,
> they can start tomorrow. Or Monday latest.
> 
> All this means they are again behind schedule. But not much and we can
> be happy to have someone who produces so small quantities for us with
> such elaborated machinery. And they have already produced many OpenPandora
> devices so they know how to solder the PoP chips.
> 
> Anyways I will take a camera with me tomorrow so that I can show some
> scenes from setting up GTA04 production then. Yeah! Here it is:
> 
> https://youtu.be/8PZOa-789eY
> 
> Everything looks good and the first boards have been populated by chips
> and connectors on the bottom side. This is the side where the display
> will be installed.
> 
> The complex top side with OMAP3, package-on-package RAM+NAND and the
> 3G module will be done on Monday.
> 
> Then we will also x-ray the boards to check if they are soldered properly
> without short circuits - and I will do the first function tests.
> 
> Let's hope that there is no hidden design bug.
> 
> BR,
> Nikolaus
> 
> It remains thrilling :)
> 
> BR,
> Nikolaus
> 
> Am 20.09.2016 um 09:04 schrieb H. Nikolaus Schaller <hns at goldelico.com>:
> 
> Am 14.09.2016 um 11:16 schrieb H. Nikolaus Schaller <hns at goldelico.com>:
> 
> Hi,
> "next week" has arrived and it looked good for Friday
> and I just waited for the final confirmation to take
> my handy-cam and make a video of the production run.
> 
> Now I got an info that everything is prepared.
> 
> But it has turned out that the dipping machine for the
> package on package memory chip is defective. It will
> be repaired and is planned to arrive on Monday.
> 
> So production run will be Tuesday or Wednesday. It is now scheduled for Thursday... We have to wait 2 more days.
> 
> Please cross fingers :)
> 
> BR,
> Nikolaus Schaller
> 
> Am 07.09.2016 um 19:21 schrieb H. Nikolaus Schaller <hns at goldelico.com>:
> 
> Next progress: it looks as if the first 20 units are built before end of next week.
> They will notify me and I can go there to make some videos.
> 
> BR,
> Nikolaus
> 
> Am 05.09.2016 um 14:26 schrieb Roland Häder <roland at mxchange.org>:
> 
> Hi,
> 
> good to hear about the progress. :-)
> 
> Roland
> 
> H. Nikolaus Schaller - Mon., 5. September 2016 13:49
> Hi,
> production time is coming very close. Last Friday we discussed the final fine-tuning for the
> stencil for printing the solder paste.
> 
> And now I got the confirmation that all components (incl. PCBs and BNO055) now have
> arrived. So I am eagerly awaiting when they have time on their production machines to
> build the first 20 units. I will go there and try to make some videos.
> 
> So you can probably feel my excitement :) And nervousness (because I don't know if
> there is still one catastrophic mistake or bug in the design).
> 
> BR,
> Nikolaus
> 
> Preorders:
> http://shop.goldelico.com/wiki.php?page=GTA04
> http://shop.goldelico.com/wiki.php?page=GTA04%20Complete
> 
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