Nordson DAGE4000 Bond Tensile Tester

3.2 Intelligent electronic features: One sensor with multiple ranges

Each load sensor stores the following calibration data internally:

Unique serial number and production date

Last five calibration records (including date, ambient temperature, pass/fail status)

Linearity correction coefficient (multi-point nonlinear compensation algorithm)

Overload history alarm flag

After the device is powered on, the host will automatically read the sensor parameters and verify whether they are within the valid calibration cycle. If the sensor is detected to exceed the calibration tolerance zone (such as strain gauge drift exceeding 0.01% due to long-term use), the system will issue a clear alarm and prevent the test from being executed, thus eliminating the generation of invalid data from the source.

The most noteworthy thing is that a single sensor can software select up to 10 different range options. By default, the factory provides four measurement ranges (such as 0-250g, 0-500g, 0-1kg, 0-5kg), and users can apply to unlock the other six customized measurement ranges (such as 0-100g for testing extremely fine gold wires). Range switching does not require hardware replacement, only the required full-scale value needs to be specified in the testing program, and the DSP chip inside the sensor automatically matches the corresponding amplification factor and filtering parameters. The minimum selectable range is as low as 5% of the full range deflection. For example, for a 10kg sensor, high-resolution measurement of 500g full range can be achieved, avoiding the additional cost of purchasing a low range sensor separately for small force values.

3.3 Friction free system and low force detection

All sensors adopt Noxin DAGE's patented frictionless bearing structure, eliminating the hysteresis and dead zone caused by traditional sliding components. In force testing below 10g (such as fine pitch gold ball shearing), the frictionless design ensures a smooth and non step like force rise curve, with repeatability better than ± 0.5g. This feature is crucial for micro solder joint testing in MEMS sensors or optoelectronic devices.

3.4 Quick release hook system

For wire testing, a quick change hook can be installed at the front end of the sensor. The hook is fixed by magnetic suction and card slot, and can be easily replaced with tools of different diameters (such as 50 μ m, 100 μ m, 200 μ m) or shapes (straight hook, curved hook, shovel shape) by pulling and inserting with bare hands. The "automatic hook finding" function provided by the system: In the microscope field of view, the operator only needs to click the mouse near the welding line, and the Z-axis will automatically drive the hook to move to the preset safe approach height, and then slowly descend until the hook accurately hooks the top of the wire arc. The entire process does not require manual adjustment, significantly improving the throughput of large-scale testing.

Comprehensive calibration mechanism: from mechanical plane to load link

Calibration is the cornerstone of ensuring the validity of test data. The Norsen DAGE 4000 provides an automated calibration system that spans the entire chain of XY plane, Z-axis depth, and load sensors, and all processes comply with ISO 9001:2008 and UKAS traceability requirements.

4.1 Test plane calibration (XY plane)

Using the randomly attached optical cross calibration plate (glass substrate, line width 2 μ m, position accuracy ± 0.5 μ m), perform the following steps:

Fix the calibration board on the workbench and adjust it to a horizontal position.

Run the "Plane Calibration" wizard, and the device will automatically move to nine feature points at the four corners and center of the calibration board.

The software calculates the deviation between the actual coordinates and theoretical coordinates of each point through image recognition algorithms, and generates a nonlinear correction mapping table.

After calibration, the absolute positioning accuracy of the system at any position within the full stroke (220mm × 220mm) is better than ± 10 μ m, and the repeated positioning accuracy is ± 5 μ m. For the precision XY platform option with a stroke of 50mm, the accuracy can be further improved to ± 3 μ m.

This calibration is recommended to be performed every six months or supplemented when the ambient temperature changes by more than 5 ℃.

4.2 Z-axis vertical accuracy calibration

The Z-axis stroke is 65mm, with a positioning accuracy of ± 10 μ m throughout the entire stroke range, and within the most critical 2mm test window (i.e. the height range from near the needle tip to the contact solder joint), the accuracy can reach ± 2 μ m. For shear testing, when using a 250g shear sensor to step down from a height of 25 μ m, the total step back to zero accuracy reached an astonishing ± 1 μ m (verified by a laser interferometer).

Z-axis calibration uses laser displacement sensors or specialized height gauges. The equipment provides a semi-automatic process: the operator places the standard block on the workbench, and the Z-axis descends at low speed until the measuring needle touches the surface of the block. The system records the reading of the grating ruler at this time. Repeat five times and take the average as the zero point. Then the Z-axis rises to different heights (such as 10mm, 20mm, 50mm), touches the standard block again, and calculates the linearity of the grating ruler. If the deviation exceeds the threshold, the software prompts to adjust the encoder compensation coefficient.