Inductive Defect Detection-Electronic Industry-Specialized in visual imaging solutions_Non-standard optical customization-Dongguan Chuangshi Automation Technology Co., Ltd

Industry background

Inductors (inductor coils) are electromagnetic sensing components wound with insulated wires, which need to go through several complex processes during the whole production process. Under the multiple processes, defects such as top and bottom misalignment, cracks, dirt, breakage and other defects will inevitably appear on the components. For the inductor appearance defects, purely manual detection, detection speed is slow, false detection rate is high. How to improve the speed and accuracy of inductor detection? Chuangshi Automation has something to say! By adding Chuangshi Automation inductive appearance inspection imaging solution to the production process or product quality inspection process, all types of defects can be easily addressed.

Industry pain points

The defects present on the inductor coil vary in location and size. The degree of contrast between the defects and the background is different under different light sources. In the light source selection, it is necessary to improve the contrast between the subtle defects and the background, so as to facilitate the image processing by the vision processing software. In hardware selection, it is necessary to carry out feature extraction for 10mm*10mm products. In the vision software, it is necessary to quickly process the collected images to improve the detection rate of problematic products, and at the same time be able to dock the enterprise production management system to complete the automatic summary of data, traceability, and help production enterprises to achieve intelligent, digital management.

Detection Difficulties

Inductors have variable appearance, many types of defects, and may appear in different positions and angles, increasing the difficulty of visual inspection;

The size of the inductor sample is 10mm*10mm, which is small and requires high-resolution image acquisition and feature extraction;

Under the conventional light source, some of the subtle defects are not obvious in comparison with the background.

Solution

The CS-Vison 2.0 identification and detection algorithm module has hundreds of built-in algorithms to meet various visual inspection needs. Algorithm software in the process of appearance defect detection without programming, selection of algorithms, set parameters to achieve the classification of different NG products to reject, a full range of coverage of inductor production process may occur in all types of defects.

In response to customer demand, in the image recognition process, the special light source of Transcend AOI is used to brighten the entire image to ensure that all kinds of subtle defects in the inductor can be clearly presented, which is convenient for the visual recognition software to carry out feature extraction, and to improve the inspection efficiency and accuracy.

Detection Effect

Dirty

In the program, for the inductor surface dirt detection found that the defects and the background chromaticity is similar, in the ordinary light source, a large area of dirt can be successfully detected, the contrast of light dirt is not obvious, in the use of AOI special light source, small pieces of dirt can be clearly distinguishable.

Crackles

In the program, for the product appeared in the upper and lower misalignment and crack two kinds of defects can be detected at the same time, the upper and lower misalignment need to lighten the whole surface to identify the contour position can be, for the large cracks, the use of ordinary light source can also be clearly identified for the small cracks, the use of AOI after the contrast of the special light source is more obvious.

Breakages

Inductor production process, broken defects in six surfaces randomly appear, for large defects, the use of conventional coaxial light source or AOI special light source effect difference is not obvious. For small pieces of broken areas, the contrast of the conventional coaxial light source is not obvious, it is recommended to use AOI special light source.

Advantages of the plan

Small defects in different locations of the product are clearly visible and contrasted. Through the combination of AOI special light source and high-definition industrial camera, the program realizes multi-faceted blind spot-free inspection of inductive products, which greatly improves the product inspection capability, and accurately detects the top and bottom misalignments, cracks, dirt, breakage and other defects in the products. Moreover, CS-Vison 2.0 identification and detection algorithm module of Chuangshi professional software is capable of judging and summarizing the massive information obtained and completing automatic optimization to accurately detect more than four different NG products, improve detection efficiency, and satisfy the production enterprises' demand for “precision” and “speed” detection. speed” inspection needs of production enterprises.