Andreas Steimer

Simon Baeuerle, Marius Gebhardt, Jonas Barth et al.

Thermal Interface Materials (TIMs) are widely used in electronic packaging. Increasing power density and limited assembly space pose high demands on thermal management. Large cooling surfaces need to be covered efficiently. When joining the heatsink, previously dispensed TIM spreads over the cooling surface. Recommendations on the dispensing pattern exist only for simple surface geometries such as rectangles. For more complex geometries, Computational Fluid Dynamics (CFD) simulations are used in combination with manual experiments. While CFD simulations offer a high accuracy, they involve simulation experts and are rather expensive to set up. We propose a lightweight heuristic to model the spreading behavior of TIM. We further speed up the calculation by training an Artificial Neural Network (ANN) on data from this model. This offers rapid computation times and further supplies gradient information. This ANN can not only be used to aid manual pattern design of TIM, but also enables an automated pattern optimization. We compare this approach against the state-of-the-art and use real product samples for validation.

Simon Baeuerle, Ian F. Mendonca, Kristof Van Laerhoven et al.

Coverage Path Planning of Thermal Interface Materials (TIM) plays a crucial role in the design of power electronics and electronic control units. Up to now, this is done manually by experts or by using optimization approaches with a high computational effort. We propose a novel AI-based approach to generate dispense paths for TIM and similar dispensing applications. It is a drop-in replacement for optimization-based approaches. An Artificial Neural Network (ANN) receives the target cooling area as input and directly outputs the dispense path. Our proposed setup does not require labels and we show its feasibility on multiple target areas. The resulting dispense paths can be directly transferred to automated manufacturing equipment and do not exhibit air entrapments. The approach of using an ANN to predict process parameters for a desired target state in real-time could potentially be transferred to other manufacturing processes.

Simon Baeuerle, Pratik Khanna, Nils Friederich et al.

Foundation Models (FMs) have shown impressive performance on various text and image processing tasks. They can generalize across domains and datasets in a zero-shot setting. This could make them suitable for automated quality inspection during series manufacturing, where various types of images are being evaluated for many different products. Replacing tedious labeling tasks with a simple text prompt to describe anomalies and utilizing the same models across many products would save significant efforts during model setup and implementation. This is a strong advantage over supervised Artificial Intelligence (AI) models, which are trained for individual applications and require labeled training data. We test multiple recent FMs on both custom real-world industrial image data and public image data. We show that all of those models fail on our real-world data, while the very same models perform well on public benchmark datasets.

Simon Baeuerle, Andreas Steimer, Ralf Mikut

Thermal management of power electronics and Electronic Control Units is crucial in times of increasing power densities and limited assembly space. Electric and autonomous vehicles are a prominent application field. Thermal Interface Materials are used to transfer heat from a semiconductor to a heatsink. They are applied along a dispense path onto the semiconductor and spread over its entire surface once the heatsink is joined. To plan this application path, design engineers typically perform an iterative trial-and-error procedure of elaborate simulations and manual experiments. We propose a fully automated optimization approach, which clearly outperforms the current manual path planning and respects all relevant manufacturing constraints. An optimum dispense path increases the reliability of the thermal interface and makes the manufacturing more sustainable by reducing material waste. We show results on multiple real products from automotive series production, including an experimental validation on actual series manufacturing equipment.

Simon Baeuerle, Jonas Barth, Elton Renato Tavares de Menezes et al.

Electronic control units (ECUs) are essential for many automobile components, e.g. engine, anti-lock braking system (ABS), steering and airbags. For some products, the 3D pose of each single ECU needs to be determined during series production. Deep learning approaches can not easily be applied to this problem, because labeled training data is not available in sufficient numbers. Thus, we train state-of-the-art artificial neural networks (ANNs) on purely synthetic training data, which is automatically created from a single CAD file. By randomizing parameters during rendering of training images, we enable inference on RGB images of a real sample part. In contrast to classic image processing approaches, this data-driven approach poses only few requirements regarding the measurement setup and transfers to related use cases with little development effort.