RS,
It seems you've been doing your homework. However, the real question is what do you need to do with AOI?
1) What is your minimum cycle time? This would help you to determine the speed you need and whether "scan on the fly" is warranted. Also, a scanning type system will have a difficult time providing high resolution as well as high throughput.
2) What is your maximum PCB size? In otherwords, why spend the money on a system with a large inspection area, if your largest assembly will never be greater than 10" x 12"?
3) What are the smallest components you plan to inspect? If your company has no plans to using 0201s, then why spend the money for AOI that will reliably inspect 0201s?
4) Are you using J-leaded parts? AOI with side mounted cameras are nice, but more cameras can lead to more variation in inspection results (false call and escapes) and more programming, as well as add to the cost. Of course, a single, downward-looking camera system will not be able to inspect a j-lead solder fillet, but with flexible lighting and sound algorithms, even slightly lifted gull-wing leads and lifted/tipped discreets can be caught with single, downward looking camera.
5) Are you building mixed technology (SMT and Thru hole) assemblies? Will you want to be able to read color codes on axial resistors? If so, color inspection will be important.
6) Do you need to have the system in-line? Off-line AOI systems can be found starting at $50K. High-speed systems that can be used both in-line and off-line start at ~$90K.
7) How much progamming time can you afford? Of course, many AOI companies tout the ability to use all types of CAD and Gerber data, but in most cases it's not without some editing. There are some AOI systems that use the same data you need to provide to your SMT mounting machines and nothing more. That can save a lot of extra programming work.
Of course, you may need a large format, high-speed, high-resolution multi-camera AOI system. Then again, there's no reason to use a $200K+ AOI "shotgun" to kill a "fly" of an inspection problem.
I would suggest putting togther a list of your requirements and sharing it with AOI vendors. It shouldn't take you long to weed through the 50+ options on the market and come up with a short list of equipment that will suit your needs.
Good luck,
MR
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