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A Binary Particle Swarm Optimization Approach Ior Routing
in PCB Holes Drilling Process

Mohd HaIiz Othman
1,2
, Amar Faiz Zainal Abidin
2
, Asrul Adam
2
,
Zulkili Md YusoI
2
, Zuwairie Ibrahim
2
, Seri Mastura Mustaza
2
, Lai Yee Yang
2

1
Faculty oI Electrical & Automation Engineering Technology,TATI University College
Jalan Panchor, Telok Kalong, Kemaman 24000 Terengganu, Malaysia
2
Faculty oI Electrical Engineering, Universiti Teknologi Malaysia
81310 UTM Johor, Malaysia

Abstract PCB holes drilling process is one oI the

manuIacturing process in making a printed circuit
board. Normally, the route chosen is dictated by
numerical controlled drill Iiles. These Iiles are
generated through computer aided design soItware,
which does not careIully consider route optimization.
This might lead to ineIIiciency oI the holes drilling
process as the robotic drilling machine might travel a
longer distance in order to complete its task. Hence,
the objective oI this paper is to model a binary particle
swarm optimization algorithm to search Ior an
optimized route in PCB holes drilling route problems.
In binary particle swarm optimization, each particle
represents a possible route Ior the drill bit to travel.
By evaluating the distance oI the route oI the particle
represented, each particle can compare and replicates
its perIormance with its personal best record and the
swarm`s best record. The result indicated that the
proposed model is better with standard particle swarm
optimization.

INTRODUCTION

In electronic industries, robotic drilling machines
have been widely used to perIorm holes drilling on
printed circuit board (PCB) in mass quantity. These
machines will choose the route based on the
Numerical Controlled Drill (NCD) Iiles provided. The
NCD Iiles listed the sequence, location and size oI
each the drilled hole. Although, these Iiles are
computer-generated, the sequences oI the drill holes
are not careIully considered. This leads to additional
distance traveled by the drill bit during the drilling
process.
The nature oI PCB hole drilling problem is
Iundamentally based on Travel Salesman Problem
(TSP). TSP highlights the dilemma oI a salesman
trying to Iind the best route Ior him to visit the entire
city with the least amount oI travel distance |1|. As
with TSP, the optimized route in PCB holes drilling
problem can be obtained by Iinding the sequence that
produce the least distance required by the drill bit to
travel in order to complete its task. An optimized
route translates to a Iaster task completion, which
directly increase the overall productivity oI PCB
assembly. Realizing the need oI route optimization
and the potential beneIit it brings, numerous
researches have been initiated in this Iield.
One oI the earliest researches on drill routing is
conducted by Kolahan and Liang in 1996 |2|. The
authors implemented Tabu search algorithm in a case
study consisting oI variable holes sizes. Then, an
improved Tabu search algorithm was proposed by the
authors in a diIIerent journal |3|. In 2005, Sigl and
Mayer introduced the 2-Opt Heuristic Evolutionary
algorithm in solving drill routing Ior Computer
Numerical Control (CNC) machine |4|. Similar as
Sigl and Mayer, Quedri et.al. used Genetic Algorithm
(GA) in searching Ior the optimized route Ior holes
cutting process in CNC machine tools |5|. Also
noteworthy are the Iindings by Kentli and Alkaya
which uses Record-to-Record Travel with Local
Exchange Moves (RRTLEM) algorithm in Iinding
optimized sequence based problems like holes drilling
and bolt assembly |6|.
The earliest literature that utilized Particle Swarm
Optimization (PSO) Ior holes drilling route problem
was written by Onwubolu and Clerc in 2004 |7|. In
2006, Zhu alarmed readers that global convergence
was not careIully considered Ior holes drilling route
problems. As particle swarm optimization tends to
converge too early, the algorithm tends to converge at
local optima instead continue searching Ior the global
optima. Thus, lead to most oI the particles being
motionless at the position. Zhu suggested an
improved PSO, Global Convergence PSO (GCPSO)
as a remedy to the problem |8|. In GCPSO, no particle
leIt inactive by randomizing the particle`s position
and velocity again. The author also introduced Order
Exchange Unit (OEU) and Order Exchange List
(OEL) as a method to select the sequence oI the holes
Ior the drill bit to travel without repeating the same
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hole twice. The proposed PSO was then tested using a
14-holes case study Irom TSP Library by Heidelberg
University. Then, in a diIIerent literature, Zhu and
Zhang has extended the research and applied the
proposed model to new problems |9|.
This paper proposed a model based on the use oI
Binary Particle Swarm Optimization (BPSO). The
model utilized the use oI linear decrease inertia
weight in eliminating the need oI Iinding the optimal
inertia weight value.
The main objective oI this paper is to explain the
application oI BPSO in holes drilling problem. At the
same time, this paper also investigates whether the
use oI BPSO will leads to better result compared to
PSO.

ROUTING PROBLEM IN PCB HOLES
DRILLING

The robotic drill arm will starts at initial position
(0,0) and travels around the PCB in order to drill all
the holes required based on the NCD Iiles provided to
it. AIter completing its task, the drill bit will return to
the initial position (0,0). The initial position is
assigned as Hole 0 in this paper.
The main objective oI the PCB holes drilling route
problem is to minimize the distance traveled by the
robot arm in drilling the holes on the PCB. As
mentioned earlier, robotic drill route is Iundamentally
based on the TSP which can be mathematically
written as Eq. (1) |10|.

(1)

where is the number oI holes required.

is the
decision variable related to the assignment oI hole
to hole . II there is movement oI the drill bit Irom
hole to hole ,

. Otherwise,

is
the cost which is the distance between hole and hole
. This can be calculate using Eq.(2).

(2)

where the coordinates oI hole is (

and hole
is (

. Note also that PCB holes drilling route

problem is a symmetric TSP where

. The
total cost is the sum oI all hole to hole costs:

(3)

Fig. 1. PCB image oI the 14 holes problem Irom TSP Library by

Heidelberg University

Figure 1 shows the case study Ior this paper. The
case study consists oI a PCB with 14 holes oI same
size. This case study is one oI the test data oI TSP
Library by Heidelberg University |11|. In the last Iew
years, it has been mentioned (but not limited to) in
Zhu`s and Kentli et.al.
Based on the case study, the initial position is
located at the top leIt corner oI the PCB image. The
cost (or distance) Irom initial position to the Iirst hole
and the last hole to the initial position are ignored in
order to adapt with the case study result. Thus leads to
a Iunction minimization equation, Eq.(4).

(4)

The optimal solution oI the case study can be either; 2
3 4 7 8 13 14 10 11 12 9 6 5 1
or 1 5 6 9 12 11 10 14 13 8 7 4
3 2 due to the symetry property it has. The cost oI
the optimal solution is 280mm.

BPSO IN PCB HOLE DRILLING ROUTE
PROBLEM

BinaryParticleSwarmOptimi:ation(BPSO)

The nature oI the original PSO is more suited Ior
continuous-valued problem. As more discrete-valued
optimization problems are introduced, the need oI a
discretevalued PSO is highly demanded. Noticing
this need, James Kennedy and Russell Eberhart have
introduced BPSO Ior binary-valued and discrete-
valued domains which introduce the concept oI
change oI change`|12|. This means that the Iunction
oI a particle`s bit velocity is no longer Iunction as the
rate oI change` oI the particle`s position, instead as
the chance to change` oI the particle`s position.
BeIore going into the particle position and
particle velocity equations, do take note that in BPSO,
each oI the bit () oI the

particle position (

)
Ior the next iteration ( ) is updated using
mathematical Iormula shown in Equation (5).

nternational Con

if

otheiwise
where

is a random number be

is the normalized velocity

particle velocity (

) Ior
( ) is updated using Eq.(6).

(6)
where,

Based on Eq.(6),

represe
memory oI its previous velocity,
weight, dictates the tendency oI t
on its previous velocity as the base
In this paper, linear decreasing iner
as it promotes a balance oI
exploitation oI the particles. This
inertia weight can be mathematicall
|13|.

where is the particle at ite

is the representation oI th
value oI inertia weight, respectively
MoaelingPCBHoleDrillingRoute

For PCB hole drilling rout
particle represents a possible solutio
The particle`s position) stores the
holes locations need to be visited b
matrix Iorm. The particle position c
to

Each hole location is represented b
Figure 2 Iurther illustrates the
representation in a binary string.
stands Ior most signiIicant bit an
least signiIicant bit.
Figure 3 shows the Ilo
application oI BPSO in PCB holes
In robotic drill route problem, the
starts by loading the holes location
Fig. 2
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(5)
etween |0, 1| and
y. Meanwhile, the
the next iteration

and

.
ents the particle`s
,

The inertia
the particle to rely
Ior the next Ilight.
rtia weight is used
exploration and
linear decreasing
y written as Eq.(7)

(7)
eration.

and
he initial and Iinal
y.
ProbleminBPSO
te problem, each
on oI the problem.
e sequence oI the
by the drill bit in a
can be generalized

by its binary value.
particle position
. Note that MSB
nd LSB stands Ior
ow chart oI the
s drilling problem.
e BPSO algorithm
ns to the program.
Then, the program initializes
particles` positions (random
velocities (set to 0).
Given a 3 holes problem
the particle suggests a solutio
5(a). In its binary representatio
rewritten as
hole #1 01, hole #210 and ho
The particle position can
represented using a radar dia
drilling route problem, the dim
( ) is equal to the product
required ( and number oI bi
the hole location ( like Eq.(8)



Fig. 3. Flow chart oI the pro

Fig. 4. Coordinates oI the

2. The particle`s position representation in a binary string

2011}
the PSO parameters,
mly) and particles`
as shown in Fig. 4, iI
on oI 1-2-3 (reIer Fig.
on, the solution can be
(where hole #000,
ole #311).
n be also graphically
gram. For PCB holes
mension oI search space
t oI number oI holes
t required to represent
).
(8)

oposed approached

e selected holes

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Fig. 5(a). Route oI the sequence: 1-2-3. (b) Graphical representation oI sequence: 1-2-3 in search space using radar diagram

Figure 5(b) is the graphical representation oI the
sequence: 1-2-3. The Iirst dimension starts at 0 degree
and represents the most signiIicant bit oI the Iirst hole
location Iollowed by the second most signiIicant bit oI
the Iirst hole location, clockwise. This continues until
the last dimension which represents the least
signiIicant bit oI the last hole location.
Then aIter particles` positions and velocities are
assigned, the Iitness oI the proposed solution by each
particle is calculated using Eq.(4). Table 1 shows how
the Iitness oI the route 1-2-3 is calculated.
The proposed model then will compare each
particle Iitness with its` personal best (). II the
current personal Iitness is better than personal best, it
is assigned as the new personal best. The swarm best
( ) is the best Iound among all the previous
particles attempted. Then, the particle velocity and
particle position updated using Eq.(6) and Eq.(5),
accordingly. The proposed model recommends that
the velocity bit oI the particle is clamped at ,3,.
During the process oI updating the particle
position, the proposed model might encounter two
problems: 1) holes redundancy and 2) out oI boundary
problem. Holes redundancy occurs when a particle
suggests a solution that requires the drill bit to visit
the same hole twice or more. A simple example to
illustrate this problem is iI
(Sequence: 1-2-1), where the particle proposes to visit
hole #1 twice.
To overcome this problem, the proposed algorithm
suggests that path to visit the next available hole is in
term oI hole order (hole #2 goes aIter hole #1). In this
case, the path become (Sequence:
1-2-3), where the third hole has been reassigned to the
next available hole, which is hole #3
Out oI boundary occurs when a particle is
positioned out oI the search space. This happens when
the particle oIIer a solution with one or more oI its
elements has a value greater than the required holes,
or less than 1. For example,
(Sequence: 0-3-2). This problem can be overcame by
choosing the hole available (in term oI hole order)
near to the boundary oI the search space. In the
example, the algorithm corrects the path as
(Sequence: 1-3-2).
This algorithm is repeated until maximum
iteration reached. The sequence will be the
best Iound result in optimizing the route.

Table 1. Calculation oI the Iitness Ior sequence 1-2-3

0 0
,0-0, ,0-0, 0 0 0
0 1
,0-3, ,0-3, 6 0 0
0 2
,0-7, ,0-6, 13 0 0
0 3
,0-8, ,0-2, 10 0 0
1 0
,3-0, ,3-0, 6 0 0
1 1
,3-3, ,3-3, 0 0 0
1 2
,3-7, ,3-6, 7 1 7
1 3
,3-8, ,3-2, 6 0 0
2 0
,7-0, ,6-0, 13 0 0
2 1
,7-3, ,6-3, 7 0 0
2 2
,7-7, ,6-6, 0 0 0
2 3
,7-8, ,6-2, 5 1 5
3 0
,8-0, ,2-0, 10 0 0
3 1
,8-3, ,2-3, 6 0 0
3 2
,8-7, ,2-6, 5 0 0
3 3
,8-8, ,2-2, 0 0 0

12








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Table 2. Comparison oI PSO parameters employed in the proposed algorithm and by Zhu et al. |10|
Zhu`s This paper
Number oI particles, 100 50
Number oI iterations, 10000 2500
Number oI computations 50 50
Inertia weight, 0.0, 0.5, 1.0
0.9 0.4
Cognitive component,

Not available 1.42

Social component,

Not available 1.42

and

Random number |0,1| Random number |0, 1|

Velocity clamping, Not available 3

Table 3. Comparison oI PSO results obtained by the porposed algorithm and by Zhu et al. |10|
Zhu`s This paper
Global Convergence PSO (Standard) PSO BPSO

0 0.5 1.0 0.0 0.5 1.0
0.90.4
The least iteration number while
global convergence (iteration)
70 601 93 - - 118 71
The average iteration number while
global convergence (iteration)
1784 3549 2104 - - 1415 783
Length oI optimal solution (mm) 280 280 280 - - 280 280
Average Iitness aIter computing 50
computations (mm)
305.7 307.3 289.6 358 359 300.7 296.0
IMPLEMENTATION AND EXPERIMENTAL
RESULT

Recall Fig. 1, the initial/home position Ior the
robotic drill machine is located at the top leIt corner
oI the PCB image shown. The BPSO model proposed
has parameters as shown in Table 2.
The simulation is perIormed 50 times on a desktop
that equipped with 2.60GHz Intel Pentium Dual Core
processor with 2GB RAM. Table 3 shows the result oI
50 computations oI the proposed model with the result
oI Zhu`s is provided as well.
The proposed model perIorms really well in term
oI speed where the average iteration number while the
global convergence is Iaster than the standard PSO
and GCPSO Ior all values. In term oI Iinding the
optimal solution, the proposed model managed to Iind
the optimal solution Ior the problem, 3 out oI 50
times.
In term oI the average Iitness aIter computing 50
computations, the proposed model able to achieve an
average oI 296.0mm. The result clearly stated that the
proposed model is better than the standard PSO. In
comparison to GCPSO, the average Iitness aIter
computing 50 computations is better Ior 0 and
05 but poorer against GCPSO with 1 .
Despite a poor perIormance against GCPSO with
1, the result also highlighted the main weakness
oI GCPSO which highly depended on the value.
Furthermore, 1 is not conIirmed as the best value
Ior the case study. The proposed model simply use
linear decrease inertia weight with value oI 0.90.4.
Thus simpliIy the need to Iind the optimal value Ior
the case study.

CONCLUSION

This paper has introduced the use oI BPSO in
solving the PCB hole drilling route problem. The
result clearly proves that BPSO has a better
perIormance compare to its predecessor, PSO Ior PCB
holes drilling route problem.
This research can be extended using ant colony
system (ACS). As the PCB holes drilling route
problem is Iundamentally based on TSP, ACS is
expected to perIorm well compared to BPSO. This
due to the nature oI ACS algorithm is Iormulated
based on the ant`s nature ability to Iind shortest
distance between two points.

ACKNOWLEDGMENT

This research was Iinancially supported by a
Science Fund grant (Vot 79361) Irom the Ministry oI
Science, Technology, and Innovation (MOSTI),
Malaysia.




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