Autoliv Night Vision System Safety Application Automotive IR Camera

Transcription

1 Autoliv Night Vision System Safety Application Automotive IR Camera Report by Farid HAMRANI & Sylvain HALLEREAU June rue la Noue Bras de Fer NANTES - FRANCE info@systemplus.fr by System Plus Consulting Autoliv Night Vision System 1

2 Table of Contents Autoliv Night Vision System 3 o Executive Summary o Reverse Costing Methodology Company Profile 6 o Autoliv 8 o Views and Dimensions of the System o System Opening o Electronic Board Top Side Global view Top Side High definition photo Top Side Main components markings Top Side Main components identification Top Side Other components markings Top Side Other components identification Bottom Side idem o Sealing Glue EDX Analysis o Sensor Unit Module Disassembly o NV3 Core Board o NV3 Personality Image Sensor o Microbolometer Board o Optical Elements Cross-Section 63 o Accessing the BOM o PCB Cost o CIS Cost o BOM Cost Electronic Board o BOM Cost Camera Module o Housing Parts Estimation o BOM Cost Housing o Material Cost Breakdown by Component Category o Accessing the Added Value (AV) cost o Electronic Board Manufacturing Flow o Details of the Electronic Board AV Cost o Details of the System Assembly AV Cost o Details of the Housing AV Cost o Manufacturing Cost Breakdown for 100k units Estimated Price Analysis 87 o Estimation of the Manufacturing Price Company services by System Plus Consulting Autoliv Night Vision System 2

3 Table of Contents FLIR ISC0901BO Microbolometer Die 4 o Executive Summary o Reverse Costing Methodology Company Profile 8 o Flir o microbolometer Characteristics 14 o Synthesis of the o Methodology o Package 19 Package Views & Dimensions Package Opening & Wire Bonding Process Package Cross-Section o Window 23 View, Dimensions Cross-Section Au/Sn Eutectic bonding o Microbolometer 31 View, Dimensions & Marking Active Pixels Compensation Pixels Cross-Section Process Characteristics o ROIC 54 o Comparison o Global Overview o ROIC Front-End Process o ROIC Wafer Fabrication Unit o Microbolometer Process Flow o Window Wafer Fabrication Unit o Packaging Process Flow 77 o Synthesis of the cost analysis o Yields Explanation & Hypotheses o ROIC 82 ROIC Front-End Cost o Microbolometer 96 MEMS Front-End Cost MEMS Front-End Cost per process steps o Window o Component 88 Bonding Front-End Cost IR Sensor Wafer & Die Cost Back-End : Final Test Cost microbolometer Component Cost Estimated Price Analysis 96 Company services by System Plus Consulting Autoliv Night Vision System 3

4 O V E R V I E W METHODOLOGY 2017 by System Plus Consulting Autoliv Night Vision System 4

5 Executive Summary o Executive Summary o Reverse Costing Methodology Based on a high definition ISC0901 microbolometer from FLIR, the Autoliv night vision infrared camera targets the high-end automotive market using two FLIR cores. Based on the solid first design from 2009, the microbolometer offers better performance in definition and frame rate. The camera also embraces the quality approach with a complex optical system and powers its night vision using sophisticated numerical processing based on an Altera field-programmable gate array (FPGA) and custom algorithm. The Autoliv night vision camera consists of two modules, the camera and a remote processing unit. The system is made very compact and easy to integrate for car makers. The ISC0901 thermal camera uses FLIR s 17µm pixel design, optimized for automotive applications. Based on vanadium oxide technology, the ISC0901 microbolometer features a 336x2256 resolution wafer level package, achieving an incredibly compact design. The ISC0901 is the automotive version of a surveillance microbolometer. By using wafer level package technology to encapsulate the microbolometer FLIR offers the best price performance ratio. This report is divided into two parts, one focused on the microbolometer and the second on the other systems. It is based on a complete teardown analysis of the night vision camera and the associated electronic control unit. Using this, it provides the bill-ofmaterial (BOM) and manufacturing cost of the infrared camera. The report also offers a complete physical analysis and manufacturing cost estimate of the infrared module, including the lens module and the microbolometer itself. The report s final component is a comparison between the characteristics of the FLIR ISC0901, FLIR Lepton 3 and the PICO384P from ULIS. The comparison highlights differences in technical choices made by the companies by System Plus Consulting Autoliv Night Vision System 5

6 Views and Dimensions o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor System s Front and Right view by System Plus Consulting Autoliv Night Vision System 6

7 Electronic Board Top Side Global View o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor Cross section of Electronic Board (XX layers) 2017 by System Plus Consulting Autoliv Night Vision System 7

8 Sealing Glue EDX Analysis o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor 2017 by System Plus Consulting Autoliv Night Vision System 8

9 NV3 Personality Board Top Side Main Components Markings o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor 2017 by System Plus Consulting Autoliv Night Vision System 9

10 NV3 Core Board Top Side Main Components Identification o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor 2017 by System Plus Consulting Autoliv Night Vision System 10

11 Microbolometer Overview o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor ROIC ROIC Package Tilted Side View 2017 by System Plus Consulting Autoliv Night Vision System 11

12 Microbolometer Silicon Window Removed The window has been de-soldered of the ROIC. o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor AuSn Sealing Frame Microbolometer with ROIC Optical View XXXXXXXXXXXXXX XXXXXXXX Optical View Solder sealing ring 2017 by System Plus Consulting Autoliv Night Vision System 12

13 Microbolometer Contact o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor M5 Contact Tilted SEM view Tungsten plug Contact Cross-Section SEM view There is a recess in the passivation likely to disengage the tops of the tungsten plugs and thus increase the contact surface between the tungsten layer and TiNiCr by System Plus Consulting Autoliv Night Vision System 13

14 Lens XXXXXXX window o Views & Dimensions o System Opening o Electronic Board o Camera Module o Image Sensor Board o CMOS Image Sensor We found the same coating on the two sides of the two lens by System Plus Consulting Autoliv Night Vision System 14

15 Microbolometer Process Flow 3/3 o Global Overview o ROIC Front-End Process o Microbolometer Process o Window Process ROIC wafer ROIC wafer Contact metal: aluminum deposition Pattern : Lithography 8 Microbridge: 2 nd absorbing layer deposition (SiN) Pattern & etch: Lithography 9 Blind Pixel: reflector deposition Pattern : Lithography 10 ROIC wafer Seal layer: gold deposition Pattern : Lithography 11 Release: sacrificial polyimide removal drawing not to scale 2017 by System Plus Consulting Autoliv Night Vision System 15

16 Microbolometer Estimated Manufacturer Price o Financial Ratios o Manufacturer Price 2017 by System Plus Consulting Autoliv Night Vision System 16

17 C O S T ANALYSIS 2017 by System Plus Consulting Autoliv Night Vision System 17

18 BOM Cost ECU Electronic Board(1/2) o Accessing the BOM o PCB Cost o CIS Cost o BOM Cost Electronics o BOM Cost Camera Module o Housing Parts Estimation o BOM Cost - Housing o Material Cost Breakdown 2017 by System Plus Consulting Autoliv Night Vision System 18

19 Details of ECU Board Added-Value (AV) Cost o Added-Value Cost o Manufacturing Cost Details of the Main Board assembly step costs by System Plus Consulting Autoliv Night Vision System 19

20 SELLING P R I C E 2017 by System Plus Consulting Autoliv Night Vision System 20

21 Estimation of the Manufacturing Price o Financial Ratios o Manufacturer Price 2017 by System Plus Consulting Autoliv Night Vision System 21

22 Related Reports o Company services o Feedbacks o Contact o Legal REVERSE COSTING ANALYSES - SYSTEM PLUS CONSULTING IMAGING Thermal Expert Infrared Camera for Smartphones Opgal Therm-App Infrared Camera & Ulis IR Microbolometer Seek Thermal Infrared Camera & Raytheon IR Microbolometer MARKET AND TECHNOLOGY REPORTS - YOLE DÉVELOPPEMENT IMAGING Imaging Technologies for Automotive 2016 Uncooled Infrared Imaging Technology and Market Trends 2016 Sensors and Data Management for Autonomous Vehicles report 2015 Camera Module Industry Report PATENT ANALYSIS - KNOWMADE Honeywell Microbolometer Patent Portfolio Analysis 2017 by System Plus Consulting Autoliv Night Vision System 22

23 COMPANY SERVICES 2017 by System Plus Consulting Autoliv Night Vision System 23

24 Business Models Fields of Expertise o Company services o Feedbacks o Contact o Legal Custom Analyses (>130 analyses per year) Reports (>40 reports per year) Costing Tools Trainings 2017 by System Plus Consulting Autoliv Night Vision System 24

25 Contact PHOENIX YOLE Inc. FRANKFURT/MAIN Europa Sales Office NANTES Headquarter LYON YOLE HQ KOREA YOLE TOKYO YOLE KK o Company services o Feedbacks o Contact o Legal GREATER CHINA YOLE Headquarters 21 rue La Noue Bras de Fer Nantes FRANCE sales@systemplus.fr Europe Sales Office Lizzie LEVENEZ Frankfurt am Main GERMANY llevenez@systemplus.fr America Sales Office Steve LAFERRIERE Phoenix USA laferriere@yole.fr Asia Sales Office Takashi ONOZAWA Tokyo JAPAN onozawa@yole.fr Mavis WANG GREATER CHINA wang@yole.fr 2017 by System Plus Consulting Autoliv Night Vision System 25