Semiconductor Assembly & Test · Recipe Remote Tuning & Process-Parameter Closed Loop
For wafer assembly / test and SMT lines, a non-intrusive gateway turns "an engineer goes to the machine to switch recipes" into "one-click remote script switching + automatic device-data read-back" — shortening changeovers and stabilising yield.
Core solution for this scenario
In semiconductor OSAT (outsourced assembly and test), Recipe (process-recipe) switching is both the most frequent operation and the one that can least afford to go wrong — a Recipe can contain dozens to over a hundred parameters, switching happens often (one machine serves multiple products), and a single misconfiguration can scrap an entire wafer lot. The "remote tuning + OCR visual verification + full-session screen recording" closed loop is therefore fundamentally about mistake-proofing rather than remote control — this is the semiconductor industry's most defining requirement for equipment networking.
I. Industry Pain Points
Typical challenges for Semiconductor / SMT Electronics Manufacturing in equipment O&M and data acquisition.
- Recipe (process-recipe) switching on assembly / test machines and placement machines has long depended on process engineers operating at the machine; across sites or countries, travel and waiting costs are high and a single changeover often takes 2–3 hours.
- Key process parameters (temperature profile, pressure, placement coordinates) are mostly manually transcribed or exported — easy to miss or misrecord, so batch anomalies are hard to trace to root cause quickly.
- Legacy placement machines and test machines often have no network port or expose no protocol, making device data naturally siloed and leaving SPC (statistical process control) and yield analysis without an underlying data source.
- Semiconductors are a tightly regulated, sensitive industry; any solution that exposes the device operator station to the public network or routes remote access through a public cloud crosses a compliance and leakage red line.
II. Solution
Build a "screen layer + protocol layer" dual-source data closed loop with the AIXOT non-intrusive gateway combination.
- APM-G220 Non-intrusive Smart Tuning Gateway takes over the assembly / test machine operator station non-intrusively via HDMI loop-out + USB keyboard / mouse emulation, enabling remote operation from the BIOS level; the controlled side needs zero installation and zero networking. Recipe switching is written as a reusable keyboard / mouse script executed remotely with one click.
- AIS-G160 Industrial Protocol Gateway acquires operating status, alarms and process parameters from placement machines, SPI, AOI and reflow ovens through its 500+ industrial-protocol library, cleans the data at the edge and reports to MES / SCADA.
- Tuning closed loop: after the G220 executes a script to switch the Recipe, AIS-T100 Video OCR Data-Collection Gateway video OCR or G160 protocol read-back captures the “screen / register” feedback; OCR verifies the execution result, forming an execute–verify automation loop with no need to watch the screen manually.
- The entire link is deployed privately; data does not leave the campus. Remote sessions are fully screen-recorded, meeting the semiconductor industry's audit and traceability requirements.
III. Deployment Steps
An executable path from interface inventory to a standardised closed loop.
- Map the target machine's operator-station video interface (HDMI / DVI / VGA) and USB keyboard / mouse path; confirm the G220 capture and emulation path
- On the G220 console, record the Recipe-switch / tuning keyboard / mouse script, adding an OCR verification node (e.g. confirming the on-screen "recipe loaded" prompt)
- The G160 connects to the placement machine / reflow oven via RS485 / Ethernet, configuring the protocol template and acquisition period, with edge anomaly pre-screening
- Gateway data is uniformly modelled through the private DVS platform, exposing standard interfaces to MES / SPC and linking the "screen layer + protocol layer" dual-source data
- Establish a changeover / tuning SOP: remote trigger script → OCR verify → data read-back → anomaly alarm, forming an auditable closed loop
IV. System Integration & Data Connectivity
Standardised connection points with MES / SCADA / PLC / quality systems.
- Connect to MES / EAP: G160 protocol data reported via OPC UA / Modbus TCP; G220 execution results written back to work orders
- Connect to SPC: continuous variables such as reflow temperature profile and placement offset enter the statistical-process-control dashboard
- Connect to the electronic batch record: key-operation recordings + OCR text precipitated as traceable records supporting yield analysis
V. Value & Quantified Metrics
Measurable benefits from the non-intrusive solution.
VI. Deployment Boundaries & Compliance Red Lines
Compliance & applicable boundaries
Semiconductor and assembly / test are sensitive industries; 4G remote access must use a private network or intranet and public-cloud connection is forbidden. The controlled device must be a PC-controlled device with HDMI / DVI / VGA video output and USB input; pure PLC / CNC dedicated controllers should use AIS-G160 Industrial Protocol Gateway protocol access instead.
VII. FAQ
High-frequency questions for the Semiconductor / SMT Electronics Manufacturing scenario.
Will the non-intrusive solution modify the assembly / test machine's original system?
No. APM-G220 Non-intrusive Smart Tuning Gateway only captures the operator-station video and emulates the USB keyboard / mouse; the controlled side installs no software and connects to no network, and the original system is completely unaffected.
Can a legacy placement machine without a network port still be acquired?
Yes. Protocol-less screen-class parameters are captured by G220 video takeover + AIS-T100 Video OCR Data-Collection Gateway OCR; devices with a serial port are acquired by the G160 via RS485 — the two paths complement each other.
How is Recipe switching guaranteed correct?
After script execution, OCR verifies the on-screen feedback (e.g. "recipe active") and is cross-checked against device-protocol read-back, forming an execute–verify loop with automatic anomaly alarm.
Does data leave the campus?
Private deployment by default; data stays on the local DVS platform. The remote link goes through the private / intranet network, meeting the semiconductor industry's data-stays-on-campus requirement.
In the 'Semiconductor / SMT Electronics Manufacturing' scenario, which CNC, PLC and injection-molding brands can G160 connect to?
AIS-G160 ships a 500+ industrial-protocol driver library, verified for CNC systems from FANUC, Siemens, Mitsubishi, SYNTEC; PLCs from Siemens, Mitsubishi, OMRON, Delta, Inovance; and injection machines from Techmation, Keqiang, Mediatek, Chen Hsong. See the 'Device Compatibility' list on this page for specific models; some legacy devices require on-site confirmation of network/extension-module conditions.
Related Scenarios & Products
Electronics Assembly / SMT
Multi-brand device data acquisition and correlation analysis
→ View ScenarioCNC Machine Tools Brands & Models Supported by G160
AIS-G160 ships a 500+ industrial-protocol driver library with native brand support for dedicated controllers (CNC, injection molding, robots) that generic gateways struggle to connect. Below are mainstream brands and models verified for data acquisition (some models require on-site confirmation of interface conditions).
| Brand | Supported Models / Comms |
|---|---|
| FANUC | All systems with an Ethernet port can communicate; for systems without an Ethernet port, on-site confirmation is required to determine whether an expansion module can be added |
| SYNTEC | System version 10.116.16X or later |
| Mitsubishi | E70, M70, M700, E80, M80, M800 |
| BROTHER | Systems with an Ethernet port |
| SIEMENS | 828D, 828DSL, 840DSL, 808D/808DSL (Ethernet-capable) |
| Haas | Full Ethernet series / full serial-port series |
| KND | Systems with an Ethernet port |
| GSK | All Ethernet-capable systems; 988 series, 25imc, etc. |
| Other Ethernet-capable brands | HNC, Mazak, HEIDENHAIN, Huazhong CNC, etc. can also be connected via the edge gateway |
PLC (Programmable Logic Controller) Brands & Models Supported by G160
AIS-G160 ships a 500+ industrial-protocol driver library with native brand support for dedicated controllers (CNC, injection molding, robots) that generic gateways struggle to connect. Below are mainstream brands and models verified for data acquisition (some models require on-site confirmation of interface conditions).
| Manufacturer / Brand | Typical Series & Models | Comms | Protocol / Driver |
|---|---|---|---|
| Siemens | S7-200 (PPI), S7-300/400 (MPI), S7-200 Smart, S7-1200, S7-1500, LOGO! | Serial / Ethernet | S7 PPI, MPI, S7comm, Modbus TCP |
| Mitsubishi | FX0/FX1/FX2, FX3U/3G, Q series (Q00J/Q00/Q02/Q02H/Q06H/Q12H/Q25H, QnU Q00U~Q26U, QnA/A series), FX3U-ENET, FX5U, QJ71E71 | Serial / Ethernet | Mitsubishi MC, MELSEC, SLMP |
| Rockwell AB | Micro800 | Ethernet | EtherNet/IP |
| LS | XGT, XGB, XBC-DN32U | Serial / Ethernet | Proprietary protocol |
| Modbus | Standard Modbus devices | Serial / Ethernet | Modbus RTU / ASCII / TCP / RTU over TCP |
| Schneider | Full range | Serial / Ethernet | Modbus RTU / TCP |
| Power utility protocols | Power utility terminals | Serial / Ethernet | IEC 60870-5-101, DNP3.0, IEC 60870-5-104 |
| HollySys | LE/LK220, LK210 | Serial / Ethernet | Modbus RTU |
| THINGET | XD/XL, XC | Serial / Ethernet | Modbus TCP |
| Inovance | H1U/H2U, H3U, H5U | Serial / Ethernet | Modbus |
| OMRON | CJ/CS, CV, CP | Serial / Ethernet | OMRON FINS, Ethernet TCP |
| FATEK | Full range | Serial / Ethernet | Proprietary protocol |
| Delta | DVP, AS228T | Serial / Ethernet | Modbus RTU / TCP |
| Panasonic | FPX, FP | Serial / Ethernet | MEWTOCOL_COM |
| Haiwell | Full range | Serial | Modbus RTU / ASCII |
| Kewei | LP series | Serial | Modbus RTU / proprietary protocol |
| Meters / Environmental / Building Automation | Smart meters, environmental monitoring, building-automation devices | Serial / Ethernet | CJ/T188, DL/T645 (2007/1997), HJ212, BACnet MS/TP, BACnet IP |
| OPC UA | Software/devices supporting OPC UA | Ethernet | OPC UA |