The fleX Line · 3D is a versatile inline X-ray system for the automatic X-ray inspection of high-end electronics. It is capable of inspecting small light as well as large and heavy assemblies fully automatically.
A special feature is the high-precision 6-axis system. It allows 2D, 2.5D and 3D X-ray imaging while the test object remains stationary. Depending on the application, the system can be equipped with either line or area detectors. A comprehensive software package offers, among other things, a wizard-based offline inspection program creation, an intuitive and app-based machine software as well as a digital maintenance concept.
The fleX Line monitors and calibrates itself. The X-ray system can be integrated into a Smart Factory of the Industry 4.0 world via various interfaces.
The comprehensive software package consists of several modules. You control the app-based machine software PILOT Inspect via intuitive touch operation in the familiar style of a smartphone. New operators can be trained in the shortest time.
The offline programming software PILOT AXI provides wizard-supported test program creation with integrated CAD data import, design library and a wide range of test functions.
The verification software PILOT Verify for classifying the detected defects displays fault images, comparison images, 2D/ 2.5D and 3D slice images as well as 3D volume reconstructions using CTview.
Networking of the AXI system with the outside world is ensured by PILOT Connect via various MES interfaces.
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Sensor technology Detector
option 1: Ultra High Speed Line Scan CCD detectors
option 2: 6 megapixel flat panel detektor
X-ray source 130 kV max. 39 W, maintenance-free Resolution
5 - 30 µm (freely selectable)
2D, 2.5D, 3D (slice images with planarCT)
Axis system Axis
X, Y, Z, U, V, W
Resolution 1 µm
max. 610 mm x 508 mm (option for 1200 mm x 508 mm)
min. 60 mm x 50 mm
0,4 mm -13 mm
max. 15 kg
Component clearance top side
max. 80 mm
Component clearance bottom side
max. 80 mm
870 mm – 970 mm
Inspection Test method
2D, 2.5D, 3D
Solder joints insufficient/excessive solder, short circuit, open circuit, voids, solder balls, lifted lead, head-in-pillow, ...
Position xy, rotation, missing, tombstone, billboard, ...
Final assembly test / battery inspection
Presence, too many/too few components, solder balls, metal residues, ... Others
Dimension (B x D X H)/ weight
1950 mm x 2002 mm x 1800 mm / 4,5 t
400 V, 3-phase / 6 bar compressed air
The fleX Line allows the inspection of DUTs with a size of up to 1200 mm x 508 mm and a weight of up to 15 kg. Standard tasks include the inspection of BGA, QFN, THT, LED and LGA solder joints. All other solder joints, whether visible or concealed, as well as press-fit connectors can be inspected in detail.
Due to the unique moving concept, in which the DUT remains stationary during image acquisition, the system can be used for the inspection of flexible printed circuit boards or also for the final inspection of mobile devices (smartphones, tablets, notebooks and wearables). The DUTs do not need to be additionally fixed. The fleX Line inspects heavy DUTs on product carriers just as reliably as loose DUTs lying in blisters or on product carriers.
The fleX Line · 3D has a precise, highly rigid, granite-based 6-axis system. The solid granite base ensures extreme straightness, flatness and parallelism. This results in a high movement speed of the image acquisition components with excellent repeatability at the same time.
► The result: ultra-clear, repeatable and consistent X-ray images for maximum defect detection in 2D, 2.5D and 3D X-ray.
The fleX Line · 3D monitors and calibrates itself - completely independently thanks to integrated tools. This ensures consistent image quality with constant measured values.
In addition, the system features a machine stability analysis tool. The permanently integrated and long-term stable feature has real solder joints of different designs and can be used to perform an MSA 1 (repeat test). The result of the MSA is an automatically generated protocol that can be used for certifications.
The AXI systems feature a digital maintenance concept. The systems create usage-based maintenance plans and monitor themselves independently.
Every key component of the machine is monitored and a detailed maintenance overview is created. A preventive maintenance plan reduces maintenance and machine downtime and thus costs. Usage-related values such as kilometres driven on the axes, pneumatic strokes and X-ray source beam hours are monitored.
When the warning thresholds are exceeded, preventive maintenance can be planned - and downtimes are reduced.
The integrated 6-axis system allows the height adjustment of the X-ray source and the detector. This enables the image acquisition geometry to be flexibly adapted to the DUT in terms of resolution and component clearance.
In addition, two detector options are available: digital area (flat-panel) and line detectors (TDI lines).
In addition to the integrated AOI camera, a full HD colour camera with wide-angle lens is built into the system. This "digital lead glass window" enables, among other things, a view into the interior during X-ray inspection.
Video sequences are recorded in a loop mode to analyse potential hardware problems in the inspection chamber afterwards. A function for automatically saving the video image when a machine fault occurs is also available. This helps the service staff to analyse the error and can provide important information about the cause in the event of a machine standstill.